Electricity Generation through Exhaust Gases

1. INTRODUCTION

Now-a-days technology is moving at a very faster rate. The conventional sources

of energy are on a verge of extinction. So scientists are merging towards the use of

non- conventional energy resources. But it also requires some kind of energy to

convert it into another form. Our project is related in utilizing the kinetic energy of

exhaust gases of vehicle which is of no use.

1.1 Introduction In I.C Engines, during the combustion process and the subsequent expansion

stroke the heat flows from the cylinder gases through the cylinder walls and cylinder

head into the water jacket or cooling fins. Some heat enters the piston head and flows

through the piston rings into the cylinder walls or is carried away by the engine

lubricating oil which splashes on the underside of the piston.

Internal combustion engines at best can transform about 25 to 35 per cent of the

chemical energy in the fuel into mechanical energy. About 35 per cent of the heat

generated is lost to the cooling medium, remainder being dissipated through exhaust

and lubricating oil.

In our project we are not using this wasted heat but we are using kinetic energy of

exhaust gasses.

1.2 Necessity

The exhaust gases of the engine are having high velocity and pressure. So by

utilizing the velocity of exhaust gases a small generator can be run which would be

capable to charge a cell phone. So, we are designing a set up which uses the high

velocity of exhaust gases to run a small gas turbine which in turn runs a small

generator which would be capable enough to generate power so that a cell phone can

be charged.

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1.3 Objective About 30 to 40 per cent heat is dissipated through exhaust gases. The heat lost

by exhaust gases has a very high velocity and pressure. So our main objective is to

utilize the kinetic energy of the exhaust gases which are being wasted. By utilizing the

velocity of exhaust gases a small generator can be run which would be capable to

generate the voltage or current which can be used for different purpose.

This set up also can be used:-

1. To operate the various vehicles accessories such as head and tail lamps, side

indicators, horn, IR sensors etc

2. Above certain speed of engine the generator gives large output than required.

So this extra output can be stored using a battery and can be used at times when the

speed of the engine is low and the output required is less.

1.4 OrganizationThe report consists of report on project “Electricity Generation through

Exhaust Gases”. First chapter consist of introduction part which contain basic review

of subject, while second chapter consists of literature survey. Third chapter contains

main topics consisting types of Parts, construction and working along with design

analysis. It is followed by performance analysis containing applications and

comparison with other materials.

Finally it is followed by the conclusion and future scope.

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2. LITERATURE SURVEY

2.1 History

For the design of the proposed model, the following considerations are made.

I. The set up is so designed that is does not have any effect on the efficiency of

the engine.

II. It can be easily mounted on the vehicle.

III. The exhaust gases can be fully utilized as possible.

IV. It must be light in weight.

V. It is simple in construction so as to fabricate locally with least available

resources and skills.

VI. It is of low cost, simple in construction and maintenance.

The following special equipments should be used in the design of

proposed model.

I. Arc welding set with 3mm welding rod.

II. Engineer’s bench and vice.

III. Metal sheet cutter and saw.

IV. Marking compass

V. Files and general engineering hand tools.

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2.2 TerminologyI. TURBINE

A turbine is a rotary mechanical device that extracts energy from a fluid flow

and converts it into useful work. A turbine is a turbo machine with at least one

moving part called a rotor assembly, which is a shaft or drum with blades attached.

Moving fluid acts on the blades so that they move and impart rotational energy to the

rotor.

There, the high velocity and volume of the gas flow from silencer is directed the

over the turbine's blades, spinning the turbine and, for so, drives their mechanical

output. The energy given up to the turbine comes from the reduction in the

temperature and pressure of the exhaust gas.

Gas, steam, and water turbines usually have a casing around the blades that

contains and controls the working fluid. Credit for invention of the steam turbine is

given both to the British engineer Sir Charles Parsons (1854–1931), for invention of

the reaction turbine and to Swedish engineer Gustaf de Laval(1845–1913), for

invention of the impulse turbine. Modern steam turbines frequently employ both

reaction and impulse in the same unit, typically varying the degree of reaction and

impulse from the blade root to its periphery.

Impulse turbines change the direction of flow of a high velocity fluid or gas jet.

The resulting impulse spins the turbine and leaves the fluid flow with diminished

kinetic energy. There is no pressure change of the fluid or gas in the turbine blades

(the moving blades), as in the case of a steam or gas turbine; the entire pressure drop

takes place in the stationary blades (the nozzles).

Energy can be extracted in the form of shaft power, compressed air or thrust or

any combination of these and used to power aircraft, trains, ships, generators, or even

tanks. Turbine - Extracts the energy from the high-pressure, high-velocity gas flowing

from the combustion chamber.

Types

Steam turbines are used for the generation of electricity in thermal power plants, such as plants using coal, fuel oil or nuclear power. They were once used to directly drive mechanical devices such as ships' propellers (for example the Turbinia, the first turbine-powered steam launch, but most such applications now use reduction gears or an intermediate electrical step, where the

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turbine is used to generate electricity, which then powers an electric motor connected to the mechanical load. Turbo electric ship machinery was particularly popular in the period immediately before and during World War II, primarily due to a lack of sufficient gear-cutting facilities in US and UK shipyards.

Gas turbines are sometimes referred to as turbine engines. Such engines usually feature an inlet, fan, compressor, combustor and nozzle (possibly other assemblies) in addition to one or more turbines.

Transonic turbine. The gas flow in most turbines employed in gas turbine engines remains subsonic throughout the expansion process. In a transonic turbine the gas flow becomes supersonic as it exits the nozzle guide vanes, although the downstream velocities normally become subsonic. Transonic turbines operate at a higher pressure ratio than normal but are usually less efficient and uncommon.

Contra-rotating turbines. With axial turbines, some efficiency advantage can be obtained if a downstream turbine rotates in the opposite direction to an upstream unit. However, the complication can be counter-productive. A contra-rotating steam turbine, usually known as the Ljungström turbine, was originally invented by Swedish Engineer Fredrik Ljungström (1875–1964) in Stockholm, and in partnership with his brother Birger Ljungström he obtained a patent in 1894. The design is essentially a multi-stage radial turbine (or pair of 'nested' turbine rotors) offering great efficiency, four times as large heat drop per stage as in the reaction (Parsons) turbine, extremely compact design and the type met particular success in backpressure power plants. However, contrary to other designs, large steam volumes are handled with difficulty and only a combination with axial flow turbines (DUREX) admits the turbine to be built for power greater than ca 50 MW. In marine applications only about 50 turbo-electric units were ordered (of which a considerable amount were finally sold to land plants) during 1917-19, and during 1920-22 a few turbo-mechanic not very successful units were sold. Only a few turbo-electric marine plants were still in use in the late 1960s (ss Ragne, ss Regin) while most land plants remain in use 2010.

Statorless turbine. Multi-stage turbines have a set of static (meaning stationary) inlet guide vanes that direct the gasflow onto the rotating rotor blades. In a statorless turbine the gasflow exiting an upstream rotor impinges onto a downstream rotor without an intermediate set of stator vanes (that rearrange the pressure/velocity energy levels of the flow) being encountered.

Ceramic turbine. Conventional high-pressure turbine blades (and vanes) are made from nickel based alloys and often utilise intricate internal air-cooling passages to prevent the metal from overheating. In recent years, experimental ceramic blades have been manufactured and tested in gas turbines, with a view to increasing rotor inlet temperatures and/or, possibly, eliminating aircooling. Ceramic blades are more brittle than their metallic counterparts, and carry a greater risk of catastrophic blade failure. This has tended to limit their use in jet engines and gas turbines to the stator (stationary) blades.

Shrouded turbine. Many turbine rotor blades have shrouding at the top, which interlocks with that of adjacent blades, to increase damping and thereby reduce blade flutter. In large land-based electricity generation steam turbines, the shrouding is often complemented, especially in the long blades of a low-pressure

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turbine, with lacing wires. These wires pass through holes drilled in the blades at suitable distances from the blade root and are usually brazed to the blades at the point where they pass through. Lacing wires reduce blade flutter in the central part of the blades. The introduction of lacing wires substantially reduces the instances of blade failure in large or low-pressure turbines.

Shroudless turbine. Modern practice is, wherever possible, to eliminate the rotor shrouding, thus reducing the centrifugal load on the blade and the cooling requirements.

Bladeless turbine uses the boundary layer effect and not a fluid impinging upon the blades as in a conventional turbine.

Water turbines

i. Pelton turbine, a type of impulse water turbine.

ii. Francis turbine, a type of widely used water turbine.

iii. Kaplan turbine, a variation of the Francis Turbine.

iv. Turgo turbine, a modified form of the Pelton wheel.

v. Cross-flow turbine, also known as Banki-Michell turbine, or Ossberger turbine.

Wind turbine. These normally operate as a single stage without nozzle and interstage guide vanes. An exception is the Éolienne Bollée, which has a stator and a rotor.

Velocity compound "Curtis". Curtis combined the de Laval and Parsons turbine by using a set of fixed nozzles on the first stage or stator and then a rank of fixed and rotating blade rows, as in the Parsons or de Laval, typically up to ten compared with up to a hundred stages of a Parsons design. The overall efficiency of a Curtis design is less than that of either the Parsons or de Laval designs, but it can be satisfactorily operated through a much wider range of speeds, including successful operation at low speeds and at lower pressures, which made it ideal for use in ships' powerplant. In a Curtis arrangement, the entire heat drop in the steam takes place in the initial nozzle row and both the subsequent moving blade rows and stationary blade rows merely change the direction of the steam. Use of a small section of a Curtis arrangement, typically one nozzle section and two or three rows of moving blades, is usually termed a Curtis 'Wheel' and in this form, the Curtis found widespread use at sea as a 'governing stage' on many reaction and impulse turbines and turbine sets. This practice is still commonplace today in marine steam plant.

Pressure compound multistage impulse, or "Rateau". The Rateau employs simple impulse rotors separated by a nozzle diaphragm. The diaphragm is essentially a partition wall in the turbine with a series of tunnels cut into it, funnel shaped with the broad end facing the previous stage and the narrow the next they are also angled to direct the steam jets onto the impulse rotor.

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Design of turbine wheel

The wheel (or turbine) is a tangential flow impulse turbine. The exhaust air

strikes the bucket along the tangent of the runner. Figure2.1 shows the runner of a

wheel. It consists of a circular disc on the periphery of which a number of buckets

evenly spaced are fixed. The shape of the bucket is of a cup or bowl. The high

velocity air of exhaust gases strikes on the cup of the runner. The buckets are made of

stainless steel spoons.

Fig. (i) Turbine wheel

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II. FRAME

The casing is design as shown in the figure. Two hose clips of 116mm diameter is

taken so that it can be mounted easily on the silencer and can be tightened as per the

requirement using nut and bolt arrangement. Four rods of 6mm diameter and 240 mm

in length are welded of the periphery of both the hose clips so that it can form a rigid

casing for mounting of other accessories.

Fig. (ii) Frame

Specification- (SQUARE)

Length-20cm

Height-5cm

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III. SHAFT

A cylindrical, usually solid metal object which commonly goes through and

holds other rotating items (e.g. pulleys, wheels, gears, bearings, sleeves) and which

may also transmit rotational forces.

Fig. (iii) Shaft

Selection of the appropriate material is an important consideration in

engineering design; that is, for some application, choosing a material having a

desirable or optimum property or combination of properties. Selection of the proper

material can reduce costs and improve performance. Elements of this materials

selection process involve deciding on the constraints of the problem and, from these,

establishing criteria that can be used in materials selection to maximize performance.

The component or structural element we have chosen to discuss is a solid cylindrical

shaft that is subjected to a torsional stress. Strength of the shaft will

be considered in detail, and criteria will be developed for maximizing strength with

respect to both minimum material mass and minimum cost. Other parameters and

properties that may be important in this selection process are also discussed briefly.

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For this portion of the design problem, we will establish a criterion for

selection of light and strong materials for the shaft.

We will assume that the twisting moment and length of the shaft are specified,

whereas the radius (or cross-sectional area) may be varied.We develop an expression

for the mass of material required in terms of twisting moment, shaft length, and

density and strength of the material.

Using this expression, it will be possible to evaluate the performance—that is,

maximize the strength of the torsionally stressed shaft with respect to mass and, in

addition, relative to material cost.

Specification-

Length - 191 mmDiameter - 9 mmMaterial - Hard MS

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IV. Circular disc It is a metal circular plate on the periphery of which vanes (spoon as a vane) is

mounted. By using forging operation 6 vanes (spoons) is mounted on the circular

plate by means of the forging operation. In this operation for welding powder is used.

with this powder welding we can easily joint the two materials like or different metals

like mild steel and stainless steel. This is most easiest way of welding.

Fig. (iv) Circular Disc

We use here mild steel plate because the weight of the mild steel (circular

plate) is more as compare to plastic plate (disk).

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Due to the use of mild steel disk the misbalancing of circular disk while the

exhaust gas bombarded on the vanes should be minimized.

SpecificationsMaterial - Mild Steel

Diameter - 50 mm

Hole - 9 mm

Slot- - 5 mm X 6

Thickness - 1 mm

Thickness of Disc - 1.5 mm

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V. SUPPORTING COLUMN These are two wooden blocks of dimension 115 *35*20 mm as shown in the

figure. Grooves are cut on both sides of the column so that it can be easily mounted

on the casing and are fixed with the help of araldite. The column is made such that,

the bearings and the motor can be easily mounted on it.

Fig. (v) Supporting Column

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VI. GEARS

Gears are machine elements that transmit motion by means of successively engaging teeth. The gear teeth act like small levers. Gears are toothed wheels used for transmitting motion and power from one

shaft to another shaft.

Spur gears or straight-cut gears are the simplest type of gear. They consist

of a cylinder or disk with the teeth projecting radially, and although they are not

straight-sided in form, the edge of each tooth is straight and aligned parallel to the

axis of rotation. These gears can be meshed together correctly only if they are

fitted to parallel shafts.

Gears of velocity ratio 3.4:1 are directly purchase from the market. The

velocity ratio of the gears is calculated as follows:

NO. OF TEETH ON DRIVING GEAR

VELOCITY RATIO =

NO. OF TEETH ON DRIVEN GEAR

T2 70

= =

T1 22

= 3.18

The gear ratio should be more as possible as so that more rpm can be

achieved, output can be increased

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(i)Gears

Terminology for Spur Gears

Pitch surface : The surface of the imaginary rolling cylinder (cone, etc.) that the toothed gear may be considered to replace.

Pitch circle: A right section of the pitch surface.

Addendum circle: A circle bounding the ends of the teeth, in a right section of the gear.

Root (or dedendum) circle: The circle bounding the spaces between the teeth, in a right section of the gear.

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Addendum: The radial distance between the pitch circle and the addendum circle.

Dedendum: The radial distance between the pitch circle and the root circle.

Clearance: The difference between the dedendum of one gear and the addendum of the mating gear.

Face of a tooth: That part of the tooth surface lying outside the pitch surface.

Flank of a tooth: The part of the tooth surface lying inside the pitch surface.

Circular thickness (also called the tooth thickness) : The thickness of the tooth measured on the pitch circle. It is the length of an arc and not the length of a straight line.

Tooth space: The distance between adjacent teeth measured on the pitch circle.

Backlash: The difference between the circle thickness of one gear and the tooth space of the mating gear.

Circular pitch p: The width of a tooth and a space, measured on the pitch circle.

Diametral pitch P: The number of teeth of a gear per inch of its pitch diameter. A toothed gear must have an integral number of teeth. The circular pitch, therefore, equals the pitch circumference divided by the number of teeth. The diametral pitch is, by definition, the number of teeth divided by the pitch diameter.

That is,

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VII. D.C GENERATOR

In electricity generation, an electric generator is a device that

converts mechanical energy to electrical energy. A generator forces electric current

to flow through an external circuit. The source of mechanical energy may be a

reciprocating or turbine steam engine, water falling through a turbine or waterwheel,

an internal combustion engine, a wind turbine, a hand crank, compressed air, or any

other source of mechanical energy. Generators provide nearly all of the power

for electric power grids.

The reverse conversion of electrical energy into mechanical energy is done by

an electric motor, and motors and generators have many similarities. Many motors

can be mechanically driven to generate electricity and frequently make acceptable

generators.

Principle:

   It is based on the principle of production of dynamically (or motional) induced

e.m.f (Electromotive Force). Whenever a conductor cuts magnetic flux, dynamically

induced e.m.f. is produced in it according to Faraday's Laws of Electromagnetic

Induction. This e.m.f. causes a current to flow if the conductor circuit is closed.

   Hence, the basic essential parts of an electric generator are:

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          A magnetic field and

             A conductor or conductors which can so move as to cut the flux

A D.C Generator of 3 volts capacity is directly purchased from the market.

Dynamo

A dynamo is an electrical 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.

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(ii) D.C. Generator

Specification-

This low speed DC electric motor rotates at about 1000 rpm at 1.5 volts and

1400 rpm at 3.0 volts.

Motor diameter: 32mm Motor casing height: 20mm Motor shaft diameter: 2mm.

Today, the simpler alternator dominates large scale power generation, for efficiency, reliability and cost reasons. A dynamo has the disadvantages of a mechanical commutator. Also, converting alternating to direct current using power rectification devices (vacuum tube or more recently solid state) is effective and usually economic.

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VIII. BEARINGS A bearing is a  machine element that constrains relative motion

between moving parts to only the desired motion. The design of the bearing may, for

example, provide for free linear movement of the moving part or for free rotation

around a fixed axis; or, it may prevent a motion by controlling the vectors of normal

forces that bear on the moving parts. Bearings are classified broadly according to the

type of operation, the motions allowed, or to the directions of the loads (forces)

applied to the parts.

Bearings may be classified broadly according to the motions they allow and

according to their principle of operation as well as by the directions of applied loads

they can handle.

Principles of operation

There are at least six common principles of operation:

plain bearing, also known by the specific styles: bushings, journal bearings,

sleeve bearings, rifle bearings

rolling-element bearings such as ball bearings and roller bearings

jewel bearings, in which the load is carried by rolling the axle slightly off-

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magnetic bearings, in which the load is carried by a magnetic field

Flexure bearings, in which the motion is supported by a load element which

bends.

Bearings of standard dimension of no. Z82g are directly purchased from the

market. No. Of bearings required are two as the turbine is mounted between

the bearings so as to rotate freely without friction.

Principle of operation

There are at least six common principles of operation:

plain bearing, also known by the specific styles: bushings, journal bearings, sleeve bearings, rifle bearings

rolling-element bearings such as ball bearings and roller bearings

jewel bearings, in which the load is carried by rolling the axle slightly off-center

fluid bearings, in which the load is carried by a gas or liquid

magnetic bearings, in which the load is carried by a magnetic field

flexure bearings, in which the motion is supported by a load element which bends

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(iii) Bearing

2.3 Mountings

i. Mounting of Supporting Column-

We are using two supporting columns of wooden block are mounted on the

casing as shown in the figure and are fixed on the rods with the help of araldite.

ii. Mounting of Bearing

Two bearings of standard dimension are mounted eccentrically on the

supporting column with the help of strips and nails.

iii. Mounting of Turbine

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The turbine is mounted between the two bearings with the help of a hollow

circular shaft.

iv. Mounting of DC Generator The D.C Generator is mounted on one of the supporting column in such a way

that gear mounted on generator shaft can easily meshed with the pinion which is fitted

on turbine shaft.

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(iv)Actual project picture

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(v) Mounting of the equipment on the two wheeler

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3.0 SYSTEM DEVELOPMENT

3.1 Electricity Generation through Exhaust Gases - As discussed above output of this device is D.C current. It consists of

frame made up of mild steel. The turbine is mounted on the shaft. At the both end of

shaft, bearing is attached. Due to these bearings the vibration of the shaft is reduced

at very great extent and output in terms of shaft rotation is obtained accurately.

Bearing is fixed between wooden plate by using press fitting method.

Wooden plates are fitted to frame by using nut and bolt. On shaft gear with 70 teeth

is mounted, and gear with 22 teeth is in mesh with it which is mounted on D.C

generator. From D.C generator two output wires are taken out.

The whole assembly is mounted on the silencer of the vehicle at the end

of muffler so as it will not affect the efficiency of the engine. The frame is made by

taking accurate dimension of silencer and maintaining some tolerance.

When the vehicle starts, Exhaust gas come out from the silencer at very

high pressure and impinge on the turbine. Due to high pressure, turbine also rotates at

very speed with shaft. Due to rotation of shaft gear with 70 teeth rotation of gear with

22 teeth which is in mesh with it is also rotated, which is mounted on D.C. generator.

Due to rotation of D.C. generator Direct current is produced. The output of the

generator at various RPM of the engine can be calculated.

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3.2 Design Calculations

When vehicle running at 20km/hr,

hw = 3.2cm We know that,g hg =w hw,

hg = (1000×0.032)÷1.25 = 25.6

Velocity of flow,Vf = (2ghg)0.5

= (2×9.81×25.6)0.5 =22.41 m/sec

Flow of exhaust gases,Mf = Vel of exhaust gasses × area at the exhaust, = 22.41× (Π÷4) × (0.02)2

= 7.04×10-3 kg/m3

Pressure measurement,Pg = g g hg

= 1.25× 9.81×25.6 = 313.92N/m2

Force measurement,Fg = Pressure × Area of exhaust = 313.92× 3.14 × 10-4

= 0.09857N.

Torque measurement,T= Force × Distance between gases striking point and axis of shaft = 0.09857 ×0 .05 = 4.92× 10-3Nm

Power measurement,P = 2ΠNT/60 = (2Π×230×4.92 × 10-3) /60 = 0.1186W

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When vehicle running at 40km/hr,

hw = 6cm We know that,g hg = w hw,

hg = (1000×0.06)÷1.25 = 48

Velocity of flow,Vf = (2ghg)0.5

= (2×9.81×48)0.5 = 30.69 m/sec

Flow of exhaust gases,

Mf = Vel of exhaust gasses × area at the exhaust, = 30.69× (Π÷4) × (0.02)2

= 9.64×10-3 kg/m3

Pressure measurement,Pg = g g hg

= 1.25× 9.81×48 = 588.6 N/m2

Force measurement,Fg = Pressure × Area of exhaust = 588.6 × 3.14 × 10-4

= 0.1848 N.

Torque measurement,T = Force × Distance between gases striking point and axis of shaft = 0.1848 × .05 = 9.24× 10-3Nm

Power measurement,P = 2ΠNT/60 = 2Π×450×9.24 × 10-3/60 = 0.4354 W

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When vehicle running at 60km/hr,

hw = 8.3cm We know that,g hg = w hw,

hg = (1000×.083)÷1.25 = 66.4

Velocity of flow,Vf = (2ghg)0.5

= (2×9.81×66.4)0.5

= 36.09 m/sec

Flow of exhaust gases,Mf = vel of exhaust gasses × area at the exhaust, 36.09×(Π÷4)×(0.02)2

= 11.14×10-3 kg/m3

Pressure measurement,Pg =g g hg

= 1.25× 9.81×66.4 = 841.23 N/m2

Force measurement,Fg = Pressure × Area of exhaust = 841.23 × 3.14 × 10-4

= 0.25567 N.

Torque measurement,T= Force × Distance between gases striking point and axis of shaft = 0.25567 × .05 = 12.12× 10-3Nm

Power measurement,P = 2ΠNT/60 = 2Π×720×12.12 × 10-3/60 = 0.9654 W

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When vehicle running at 70km/hr,

hw = 9.7cm We know that,g hg = w hw,

Hg = (1000×.0.097)÷1.25 = 77.6

Velocity of flow,Vf = (2ghg)0.5

= (2×9.81×77.6)0.5

= 39.02 m/sec

Flow of exhaust gases,Mf = vel of exhaust gasses × area at the exhaust, = 39.02× (Π÷4) × (0.02)2

= 12.13×10-3 kg/m3

Pressure measurement,Pg = hg g hg

= 1.25× 9.81×77.6 = 951.57 N/m2

Force measurement,Fg = Pressure × Area of exhaust = 951.57 × 3.14 × 10-4 = 0.2987 N.

Torque measurement,T= Force × Distance between gases striking point and axis of shaft = 0.2987× .05 = 14.94× 10-3Nm

Power measurement,P = 2ΠNT/60 = 2Π×940×1494 × 10-3/60 = 1.4754 W

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When vehicle running at 90km/hr,

hw = 11.9cm We know that,g hg = w hw,

hg = (1000×.0.097)÷1.25 = 95.5

Velocity of flow,Vf = (2ghg)0.5

= (2×9.81×95.2)0.5 = 43.22 m/sec

Flow of exhaust gases,Mf = vel of exhaust gasses × area at the exhaust, = 43.22×(Π÷4)×(0.02)2

= 13.58×10-3 kg/m3

Pressure measurement,Pg = g g hg

= 1.25× 9.81×95.5 = 1220.12 N/m2

Force measurement,Fg = Pressure × Area of exhaust = 1220.12 × 3.14 × 10 = 0.38312 N.

Torque measurement,T = Force × Distance between gases striking point and axis of shaft = 0.38312× .05 =19.20× 10-3Nm

Power measurement,P = 2ΠNT/60 = 2Π×1230×19.20 × 10-3/60 = 2.47 W

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Calculation table-

Particulars/speed 20 40 60 70 90

hw ( cm) 3.2 6 8.3 9.7 11.9

hg ( m) 25.6 48 66.4 77.6 95.5

Vf ( m/s) 22.41 30.69 36.09 39.02 43.22

Mf ( kg/m3) 7.04× 10-3 9.64× 10-3 11.14× 10-3 12.12× 10-3 13.18× 10-3

Pg ( N/m2) 313.92 588.6 841.23 951.57 1220.12

T ( Nm) 4.92× 10-3 9.24× 10-3 12.12× 10-3 14.94× 10-3 19.20× 10-3

P ( W) 0.1186 0.4354 0.9654 1.4754 2.47

Table (i) Calculation Table

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3.3 Testing of Proposed Model-

Different readings at different RPM of the engine are noted as shown below in

the table.

SR.NO SPEED

In

km/hr

OUTPUT OF

GENERATOR

in Volts

CURRENT

in Ampere

POWER

DEVELOPED

(V *I) in W1 20 2.17 0.06 0.1302

2 30 3.75 0.10 0.375

3 40 4.98 0.19 0.9462

4 50 6.28 0.26 1.6328

5 60 7.46 0.30 2.238

6 70 8.16 0.34 2.775

Table (ii) Testing of Proposed Model

O/P table As shown in the table when the rpm increases the electricity generation or energy

generation also increases. The energy output of vehicle is directly proporational to the

rpm of the vehicle.

Different vehicles have different exhaust gas velocity so the reading may vary

from vehicle to vehicle. As the rpm of vehicle increases the output power of dc

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generator increases. And it is directly proportional to the cc of the vehicle as the cc of

the engine increases the energy output is also increases.

Fig (vi) Speed vs Torque Graph

The above figure shows the Speed and Torque Graph. It shows that the Speed

of Pelton Wheel increases, the Torque of Generator decreases and vice versa.

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3.4 Cost Estimation-

A) COMPONENT CAN BE USED

SR. NO. COMPONENT QUANTITY PRICE TOTAL

1 GENRATORS 1 70 70

2 HOSE CLAMP 2 60 120/-

3 SPUR GEARS 2 100 200/-

4 BEARINGS 2 60 120/-

5 SPOONS 6 12 72/-

6 CIRCULAR DISC 1 25 25/-

7 WIRE(15ft) 1 30 30/-

TOTAL 657/-

Table (iii) Components Used

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B) COMPONENTS FABRICATED

1) MATERIAL COST

SR. NO. COMPONENT QUANTITY RATE TOTAL

COST

1 M.S ROUND BAR

6MM DIA.

4 15 60/-

2 WOODEN PLATE 2 50 100

TOTAL RS. 160/-

Table (iv) Material Cost

2) LABOUR COST

SR. NO. OPERATION

PERFORMED

PRICE

1 WELDING 150/-

TOTAL RS. 150/-

Table (v) Labour Cost

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3) OTHER EXPENSES

SR. NO. PARTICULARS PRICE

1 ARALDITE 40/-

2 FEVI-QUICK 25/-

3 PETROL 500/-

4 NAILS 25/-

5 WIRE 15 FT. 30/-

TOTA

L RS. 620/-

Table (vi) Other Expenses

TOTAL COST OF MODEL = COST OF COMPONENT PURCHASED +

COST OF COMPONENT FABRICATED

= 657 + (150 + 160 + 620)

= RS. 1587/-

3.5 Action PlanActivities completed till date are

1. Problem identification.2. Literature survey.

ACTION PLAN FOR BALANCE ACTIVITIESSR. NO

.

ACTIVITIES

JANUARY 2013

FEBUARY

2013

MARCH2013

APRIL2013

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Week 1 Week1-2

Week 3-4

Week1-2

Week 3-4

Week1-2

Week 3-4

1. Additional data collection to identify any other problems.

2. Finalize list of problems and Analyze the problems

3. Designing of turbine, frame. gear ratio etc.

4. Planning of assembly and correct mounting of each component

5 Study the mechanisms involved and decide corrective actions after each problem.

6. Collecting components which available in market

7. Report writing.

Table (vii) Action Plan

4. PERFORMANCE ANALYSISGECA Page 38

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4.1 Advantages-1. It requires no external power to drive the generator.

2. Increased efficiency of the engine with the same input.

3. Its weight does not have any effect on the efficiency of the engine.

4. Can be easily carried along with the vehicle.

5. It is simple in construction so as to fabricate locally with least available

resources and skills.

6. It is of low cost and low maintenance.

7. It does not give back pressure on engine.

8. It does not affect the performance of engine.

9. Capital cost is low.

10. There is no maintenance due to there is no friction available between

moving parts.

4.2 Drawbacks-

1. This Model is restricted for Two wheeler only.

2. Construction is not Compact.

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It is basically designed to generate electricity this electricity we can be use it

1. To charge cell phone.

2. To operate the vehicles various accessories such as head and tail lamps, side

indicators, horn IR sensors etc.

3. Above certain speed of engine the generator gives large output than required. So

this extra output can be stored using a battery and can be used at times when the speed

of the engine is low and the output required is less.

4. It can also be use to charge digital cameras, I-Pod etc.

4.4 Comparison

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Sr.No Parameters Our Device Battery

1. Supply No Supply needed Charging is required

2. Maintainance No More

3. Volt 16 V for 100 cc Bike

(changes with speed)

8 V for 100 cc Bike

4. Pollutant It uses pollutant It creates Pollutant

5. Life More Life Less Life

6. Cost Low Cost High Cost

7. Other No Acid Required Acid Required

8. Use It can be connected to

Power producing

Device.

It can be connected to

Power consuming Device.

8. Application Can also be used in

Remote Areas.

Automobile

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5.0 CONCLUSIONS

5.1 Conclusion-

This Project is very advantageous and uses the Principle of

Conservation of energy i.e One form of energy is converted to another

useful form. The Exhaust which is of no use, is used to produce

Electricity which may be used for lighting Headlamp, Tail-lamp,etc.

The Engine Performance is not affected by this device.

Moreover the efficiency of the Engine is increased as exhaust which is

of no use, is used to generate Electricity.

It requires no external power to drive the generator.

The weight of this Device does not have any effect on the efficiency of

the engine.

Increased efficiency of the engine with the same input.

This is a very economical Device and can be used in all Two Wheelers

by making some changes in the Frame.

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5.2 Future Scope-

By further modification, of this set up can be also be used for various purposes as

follows:

To operate the vehicles various accessories such as head and tail lamps, side

indicators, horn etc.

Above certain speed of engine the generator gives large output than required.

So this extra output can be stored using a battery and can be used at times

when the speed of the engine is low and the output required is less.

This set up also can used at chimney sugar industry, thermal power plant, in

bathrooms at tap etc output can be used for various purposes.

The Design of this Device can be made Compact.

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REFERENCES

(i) Design of machine elements Second edition Tata Magraw Hill.

(ii) I.C Engines By V. Ganeshan

(iii) Machine Design By Khurmi and Gupta

(iv) http://en.wikipedia.org/wiki/Gas_turbine

(v) http://en.wikipedia.org/wiki/Bearing_(mechanical)

(vi) http://en.wikipedia.org/wiki/electric D.C. generator.

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