Alternative Power Source: V-Belt Fuelless Power Generating Set
Adewumi, Idowu Olugbenga
DEPARTMENT OF AGRICULTURAL ENGINEERING, FEDERAL COLLEGE OF AGRICULTURE MOOR PLANTATION IBADAN
OYO STATE NIGERIA
E-mail: [email protected], +2348023821869
Abstract: A fuelless generator is a mechanical device that generates electric power without the use of fossil fuel. The objective of
this research work is to construct and evaluate the performance of a 1KVA fuelless generator using V-belt as a means of power
transmission. The materials used for the project work includes: D.C motor of 2.5Hp, alternator of 950watts, pulleys of 3inches
and 9inches, V-belt, 12V/75Ah battery, 50µF capacitor and 15Ah charging panel. The method involved fabricating a frame made
of angle iron of length 56mm, width of 45mm and height of 26mm: braided at different points for regularity with angle bar,
fabrication of shaft on the D.C motor, fixing pulley of 9inches on the D.C motor shaft and pulley of 3inches on the alternator
shaft, connecting the two pulleys with V-belt well tensioned. The positive and negative terminals of the D.C motors and charger
are connected to the positive and negative terminals of the battery to the mains as output. The charging panel and the capacitor
were connected to the alternator for better current recycling. The machine consists of five different units: power unit, conversion,
control, output and charging unit. The result of the performance evaluation of this work shows that, the machine has an average
efficiency of 56.92% at load of 500watts. The peak efficiency of the constructed V-belt fuelless generating set was 71.42% at load
of 100watts.
Index Term - Generator, fuelless, V-Belt, alternative energy
1. INTRODUCTION
Nigeria’s public power company–power
holding company of Nigeria has an installed
generating capacity of about 6GW but actual
available output is less than 5GW power
black- out is frequent. Presently power
generating is mainly from thermal
plants(About 61%)while hydro power
generating
is about 31%.Most of the
generating assets in the public power sector
are old, between 18 and 43 years. Lack of
timely routine maintenance had caused
significant deterioration in plant output and
is a key explanatory factor in the lingering
electric power crisis. According to industry
watchers more than two decades of poor
planning and underinvestment had left a
huge supply deficit. There was no new
infrastructure in over a decade despite rapid
population growth and rising demand for
power. (Nigeria; Electric power sector report
2008). Ajav, (2012) as cited by Adewumi
(2014) has discovered that environmental
pollution which leads to degradation or
delection of ozone layer is one of the major
problems caused by the use of generator
with fossils fuels. Other problems include
land and water pollution, noise pollution,
increase in price of fossil fuel year in, year
out, among others.
In order to find other ways of producing
energy, a number of alternatives has arises
from non-conventional energy sources that
are renewable. Bhim et al (2006) has noticed
that one of these alternatives is the
generating of electricity from a fuelless
engine, in an isolated power generation
system with low maintenance cost Hubert,
(1991) as defined a fuelless engine as an
engine that produces electricity without fuel
(petrol, diesel, oil, grease, gas e.t.c). The
driving mechanism is the DC motor, which
is driven by a battery (12V or more). The
battery drives the DC motor, which in turn
spins the alternator to produce electricity
and at the same time, with the help of the
diode, it recharges back the battery (Roland,
2008). It requires a suitable controller to
regulate the voltage due to variation of
consumer loads. There are several different
type of engine and all have different uses on
the road, in the air, on the water, under the
ground, in the hospitals and behind the data
centers (Kurtus, 2012), fuelless engine can
replace any of these engine types. Fuel-less
engine has very little impact on the
environment, noiseless, pollution free, selfdependent; it can be built to the capacity of
the load you want it to carry. (Ajav and
Adewumi, 2014).
This research work covers construction of a
1KVA(1000W) V-belt type of fuel-less
generating set for use in rural area, in order
to minimize the issue of erratic power
supply and achieving rural electrification.
The limitation of this project is that it is
limited to a maximum output of 1KVA of
electric power.
Oliver et al (1991) has intensively
investigated other method
of
power
generation including a charged particle
collector
patented
in 1901. Fuelless
generator is a device that is understood to
function without the need for internal
combustion engine which usually request for
fuel as a source of input (Ajav and
Adewumi, 2014). Even so, the concept of a
mass produced fuelless engine has remained
an interesting preposition to engineers today.
Ajibola (2009) noticed that Nigeria scientist
started their own work on fuelless generator
around year 2009 with all the materials
needed for the production sourced locally.
The newest and most promising renewal
energy technology competing with selfcharging inverters is the fuel-less engine,
though costlier than the latter. The selfcharging inverters could be in modules of
5000 watts while fuel-less engines could be
designed and constructed to the two- thirds
of the 500hp (373kw) capacity of the DC
motor that drives the alternator thereby
producing
333hp
(248.7kw)
output
(Sadamichi et al, 2012). It was observed that
the output remains constant the irrespective
of the number of the batteries used starting
from one or two batteries to produce 24
Volts that drives the DC motor although
using two numbers of 200AH deep cycle
batteries drives the DC motor faster than
using two numbers of 100AH deep cycle
batteries. Once the rate of discharging the
batteries is equal to the rate of charging the
batteries than the output voltage remains
constant and the fuelless engine could
operate 365 days without any interruption.
This is an ideal renewable energy source.
The source of energy comes from within the
realm of physics but there is an opposing
challenge to the first law of thermodynamics
which is generally referred to as principle of
law of conservation of energy. The
techniques to generate electricity out of this
fuel-less engine has been tested and proved
reliable and steady (Oloyo, 2001).
2. Potential of Fuelless Generator
The application of fuel-less engine to
generate electricity is restricted to capacity
of both the DC motor and the alternator.
This implies that the availability of DC
motor and alternator of large capacitor gives
the fuel-less engine its potentials (Theraja et
al, 2007). Research has shown that the
potential for fuel-less engine globally is
more than five times the potential of wind
and solar for the fact that it works
throughout a day basis in any part of the
world, and several DC motors are
manufactured of through the world.
Advantages
of
a
Fuelless
Generator over Gasoline Generator
i
The energy produced is clean and
non-polluting
ii
There is no carbon monoxide or any
other by products released, it
produces no green house gases or
other waste.
iii
It is a renewable energy that will
help reduce our reliance on the burning of
fossil fuels.
iv
The electricity supply is constant
and efficient.
v
It needs no fuel.
vii
cost.
Insignificant or low maintenance
viii
Occupies under area than selfcharging inverters.
ix
Isolated energy generation.
x
Possesses no threats to life and
properties (Rajaendra et al,2012)
Electric Transformer
James (2005) claimed that electrical
transformers are used to transform electrical
energy by altering voltage, generally from
high to low. Voltage is simply the
measurement of electrons, how many or
how strong, in the flow. Electricity can then
be transported more easily and efficiently
over long distances. Power line electrical
transformers are commonly recognized,
because there are other various types and
sizes as well. They range from huge, multion units like those at power plants, to
intermediate, such as the type used on
electric poles, and others can be quite small.
Those used in equipment or appliances in
your home or places of business are smaller
electrical transformers and there are also
tiny ones used in items like microphones
and other electronics (Grafham, 2013).
The materials used for the construction of
the fuel-less generator were sourced locally
from various markets in Ibadan (Ogunpa and
Dugbe). This was aimed at reducing the
overall cost of the machine to the minimum
affordable cost. The machining process
involves in producing each components
parts of the machine are: cutting, drilling
machine, welding machine, grinding,
turning on the lathe machine and other
associated manual fittings.
3.1
Materials
Material selection is one of the foremost
functions of effective engineering designs as
it determines the reliability of the design in
terms of industrial and economical aspects.
A great design may fail to be a profitable
product if unable to find the most
appropriate materials combinations. So, it is
vital to know what the best materials for a
design for the purpose of the work, the
properties of the materials which are
identified as the potential materials for that
specific design (Fatai, 2013)
current (AC), removal of ripples, and
rectification.
Fuelless Power Generating Set
Components Units
Where,
The fuelless power generating sets consists
of five major units, which includes the
following;
1.
2.
3.
4.
5.
The power supply unit
Conversion unit
Control unit
Output unit
Charging unit
The size of the alternator been used, will
determine the capacity of the generating set.
Mathematically;
P = IV cos Ø
P = Power Output (Watts) = ?
V = Voltage (Volts) = 220
I = Current (ampere) = 5.35A
Cos Ø = 0.85
Therefore, the capacity of the generating set,
P = 5.35 × 220 × 0.85 = 1000W
The alternator which is a small domestic
generator has four output lead cables which
supplies, the load, capacitor and the charger.
The Power Supply Unit
12 volts battery was used as source of power
supply unit to the D.C motor in order to
induce electromotive force (e.m.f). Lead
acid battery is highly recommended for DC
generating system. This serves as storage
device for the direct current which is to be
induced
Conversion Unit
This unit is the unit that distinguished the
D.C generator from the popular fuelled
generating sets. The unit makes use of DC
motor, which will be responsible for all
voltage, current and power conversion.
Control Unit
This unit performs the following works;
converts direct current (DC) to alternating
Output Unit
The use of the control circuit unit will make
it possible to provide output voltage within
the range of 100V – 240V which is the
standard voltage requirements for all
appliances. The black cable on the alternator
was used to supply the household and
offices as the mains.
Constructional Features.
The constructional features are as discussed
below:
The Frame
This part provides supports to all
components of the fuel-less generator. It
serves as an housing for all components
parts of the machine. A piece of angle iron
56mm × 56mm × 5mm was measured, cut to
sizes and welded together to make a stand of
length 56mm, width 45mm and height
26mm; braced at different points for
regularity with angle bar of 1.5mm ×
1.5mm.
The Motor Seat
A piece of angle iron of dimension
mentioned for the frame was cut into length
25mm × 12mm and which was welded to
the main frame as shown in appendix.
Alternator Seat
A piece of angle of the above dimension
(1.5mm × 1.5mm) from the frame was cut
into length 27mm × 15mm and was welded
to the frame.
Battery and Charging Panel Seat
The plate was measured and cut into the
length of 53mm × 21mm and welded tot the
frame to make up with the seat of battery
and the self charging panel of the generating
set.
COMPONENT PARTS
Alternator
A permanent alternator is a powered
generating device that produces a sinusoidal
output when a mechanical input to its hub or
shaft is applied. This device is constructed
very much like a brushless motor with the
appropriate selection of insulation materials
and winding to match the environment and
application.
The alternator used for this research work
has the following nominal parameters as
specifications; Voltage = 12V,
Current = 5.3A
Speed = 6000rpm,
Minimum speed for accumulator charging
initiation = 1300rpm.
They are produced in a variety of power and
voltage levels and generally are always
examined from many points of view, such as
reliability, efficiency, dimensions, weight
and costs (McGraw-Hill, 1999).
D.C Motor
Electric motors are electric generators
reversed in function. The converts electrical
energy into mechanical energy – the
continual stresses between two
electromagnetic field relatively movable,
just as generator converts into
electromagnetic stresses, the mechanical
energy applied to them (Adewumi, 2013).
Power from the electric motor is transmitted
into the alternator using pulley via V-belt
(Justin, 2011). Electric motor used for this
research work has the following
configurations; 9000rpm (speed), 12V.
Battery (Dry Cell)
A common battery (dry cell) is a device that
changes chemical energy to electrical
energy. It consists of an outer case made of
zinc (the negative electrode), a carbon rod in
the center of the cell (the positive electrode),
and the space between them is filled with an
electrolyte paste (Steve, 2007). The battery
used in this construction is a Lead-Acid
accumulator cell of 12V, 75amps capacity.
Charging Panel
This is a component that recharges and
recycles the electric current produced by the
alternating device in the operation process.
It is used to put energy into a secondary cell
by forcing an electric current through it (Ed
Gray 2002).The charging protocol depends
on the size and type of the battery being
charge.
However, the battery charger used in this
design is rated as follows;
Input = 240V, 50Hz,
Output = 12V D.C, 15A
Pulleys and Belt
The pulley is a circular metallic wheel on
the axel that is designed to support
movement and change of direction of a
cable or belt along its circumference (Elroy
et al 2003). In this construction, the pulley
used is 9inches diameter on the DC motor
and 3inches diameter on the alternator. The
pulley on the D.C motor is made of
aluminum while that of alternator is made of
iron. Belt is a loop of flexible material used
to mechanically link two or more rotating
shafts, most often parallel. It is used as a
source of motion to transmit power
efficiently (James, 2010). The belt used in
this construction is V-belt, 38mm diameter.
Load Box
To know the efficiency and the capacity of
the generating set there is need for a load
box. The load box consists of points of
currents consumption with specific power
requirement. It consists of bulbs of equal
power in ‘watts’ each of the bulbs has its
own control switch which enables the ‘on’
and ‘off’ process. The components of the
load box used in the evaluation of this work
are:
 Plywood
 Five lamp holders
 Five single-gang switches
 Five bulbs (four 200watts and one
100watts.)
 1.0mm cable
TOOLS AND EQUIPMENTS USED FOR
CONSTRUCTION
Cutting Machine: The cutting tools was used to
cut metal sheet to different dimensions.
Grinding Machine: With the use of this
machine, all welding joints were smoothen for
proper fitness where needed
Welding Machine: This machine was used to
join various broken parts of the machine.
Hammer: To straighten bents of metals parts
before and after joining.
Screw Driver: This is used to tighten and
loosening of screws in the assembly of
machines.
Lathe Machine: With the use of this machine,
metals were turned into shaft of suitable
diameter of various uses.
Vernier Caliper: This was used to measure
the internal and external diameter of a shaft.
DESIGN ANALYSIS
(i)
Torque Transmitted by D.C motor
(T)
T = 9.55p/n (Diabana, 2006)
Where P is D.C motor power torque
n = number of revolution per minute
of the D.C motor.
(ii)
Determination of shaft torque.
T = (T1 – T2)/2
(iii) Determination of the power of the
machine.
P (Power of the D.C motor) = IVCos
Ø
Where I = Current in Ampere
V = Voltage in volts
Cos Ø is file, which is = 0.85
(iv)
Torque required to overcome
friction.
T=P×
(v)
= w tan (Ø - )
Resistivity
(R) =
R = Resistance (Ώ)
P = Resistivity (Ώm)
L = Length of the conductor
Where
R = 1.7 x 10^ -8 Ώm x
18.55/20
R = 1.58 x 10^ -8 Ώ
Power of the load box
P = I2 x R
R (Resistance) = 1.58 x 10^ 8Ώ
I (Current) = 10.55A
P = 10.552 x 1.58 x 10^-8 Ώ
P = 1.67 x 10^ -8w
DESIGN PROCEDURE
Step 1:
shaft was fabricated to the DC
motor in linear direction to the alternator.
Step 2:
Pulley of 3inches was fixed on
the crankshaft of the alternator.
It was fastened with the use of a
metallic key having a specified
length and diameter suitable for
the key space on the alternator.
Step 3:
A pulley of 9inches diameter
was also fixed on the crankshaft
of the D.C motor.
Step 4:
For the purpose of torque
transmission from the D.C motor
to the alternator, a V-belt of
38mm was introduced.
Step 5:
Constructing a frame for the
generator to provide support and
rigidity.
Step 6:
The capacitor was connected to
the yellow cables.
Step 7:
Connecting the terminals of the
DC motor to the equivalent
terminals of the battery.
(m)
A = Cross sectional area of
the conductor (m2)
From T = 9.55P/n
Assuming revolution per minute of the DC
motor is 1,440
Power of the DC motor is 2.5Hp
1Hp = 0.764Kw
2.5Hp = 1.87Kw
P = 1.87
n = 1440
T = 9.55 x 1.87/1440
T = 0.0124Nm
Resistivity of the wire of the load box
Resistance (R) =
P = 1.7 x 10^ -8 Ώm
L = 18.55m
A = 0.02mm = 20m
RESULT AND DISCUSSION
The data in the table below was derived
from 1KVA pulley/V-belt fuel-less
generating set. The evaluation of the fuelless generating set was done by loading it
with varying loads that range from 0watts to
500watts bulbs for a time of 300seconds for
each load. The voltage of the generator was
taken with the use of digital multi-meter.
From the table below, it is observed that as
the voltage reduces while the current
increase. This result support Ohm’s law
finding that states that, the higher the
voltage in the circuit, the higher the current.
Table: 1
generator.
Input
Output Efficiency of fuelless power
Trials
Load
Output Input
(W)
Current
(%)
Current
1
0
0
2
0.28
3
81.14
12.76
0
(V)
(W)
183
0
0
100
12.66
174
48.30
71.42
5.34
200
12.79
54.24
161
67.00
6.34
67.64
0.34
Output
Efficiency
Voltage
Voltage
Power Power
(V)
(A)
(A)
(W)
0
Input
Output
4
106.34
300
69.21
12.75
65.05
145
8.34
0.48
5
119.09
400
69.10
12.66
62.34
124
8.78
0.55
6
118
500
67.6
12.70
56.92
103
9.34
0.65
Machine Evaluation
In accordance with the Table 1 the
evaluation of the machine is calculated using
the formular below:
i. Input power = Input voltage x
Input current
i. Output power = Output voltage x
Output current
ii. Efficiency =
With the use of the multi-meter as a
measuring device, the input voltage, ou tput
voltage, input current and output current
were determined.
Evaluation Procedure
The load box was connected to the fuelless
generator in order to power the light bulbs
on the box which was connected to the dash
board of the generating set with the use of
an extension cable. Stop watch was used to
record the time at interval of 60 seconds for
five different runs with different load
quantity, detailed in the appendix tables.
While the multi-meter was used to read the
voltage output in volts with current in
ampere and the mean voltage with current
result was computed in Table 4.0 above.
Plate 1:
Testing of the constructed
fuelless generating set.
iii.
iv.
CONCLUSION
The need for new energy sources had led to
a number of alternatives with their attendant
teething high cost problems. However, in the
future, if the technology is further developed
and embraced, the costs will reduce to
compete reasonably with those of generator.
Fuel less engine is a renewable energy
source with insignificant or no carbon
dioxide emissions when sparking occurs at
the battery terminals as a result of partial
contact when wiring .mostly, the fuel less
engine potential can be utilize by merely
replacing all the generating set electric of
fuel powered motors with DC motors and
adequate chargers.
RECOMMENDATION
In consideration of the performance of the
generating set during its evaluation, the
following recommendations were made for
better and viability of the generating set.
i.
ii.
A battery well above 12V should be
used to power the D.C motor in order
to obtain good performance
characteristics.
According to the performance
evaluation test, we discovered that
the D.C motor is not in good
working condition. Therefore, to
overcome unforeseen breakdown of
the generating set a new D.C motor
should be used.
Due to the average efficiency
possessed by the machine at the load
of 500watts, the generating set
should therefore be used for
lightening only.
The appliance can be adopted and
made available for use in agricultural
establishment.
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Adewumi, I.O obtained his B.Sc. degree in Industrial
and Production Engineering from Faculty of
Technology, University of Ibadan, Nigeria in
2009. He completed his M.Sc. degree in Agricultural
and Environmental Engineering (Farm Power &
Machinery Option) from Faculty of Technology,
University of Ibadan, Nigeria in 2014. Currently he is
a prospective P.hD Student of University of Ibadan,
Nigeria. He is a lecturer in the Department of
Agricultural Engineering, Federal College of
Agriculture, Ibadan Nigeria. He has published many
research in the area of computer modeling, ICT &
agriculture and renewable energy system.
Correspondence:[email protected],
[email protected]. Tel: +2348023821869