DEVELOPMENT AND FABRICATION OF ELECTROMAGNETIC ENGINE

Submitted by

Avin Ganapathi

Rithin R

Srinivas Rangan L

Vinay M1

2

A PROJECT WORK PROPOSAL ON

DEVELOPMENT AND FABRICATION OF ELECTROMAGNETIC ENGINE

Submitted ByAVIN GANAPATHI(4MH09ME010)RITHIN R(4MH11ME094)SREENIVAS RANGAN L(4MH11ME104)VINAY M(4MH11ME118)

Under the Guidance ofProf. B HARISHAssistant ProfessorDepartment of Mechanical EngineeringMIT Mysore

DEPARTMENT OF MECHANICAL ENGINEERINGMAHARAJA INSTITUTE OF TECHNOLOGY

MYSORE - 571438

Index

1. Introduction

2. Literature survey

3. Overview

4. Components and description

5. Design Calculations

6. Fabrication and Assembly

7. Cost estimation

8. Testing3

9. Result

10. Conclusion and Scope for future development

References.

Fabricated model photographs

4

Introduction

• Conventional Engine ConceptAn Internal Combustion is an engine

where combustion of fuel occurs with an oxidizer in combustion chamber that is an integral part of working fluid flow circuit.

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Drawbacks of IC engine

• Air pollution.• Because of high demand and decreasing

supply, the price of fuel is increasing.• Running cost Maintenance cost is high.• Manufacturing cost is high.

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Windings on coreThe force that sets up the magnetic field depends

on the number of turns on the coil and the magnitude of the current flowing. This force is called the Magneto Motive Force and is measured

in Ampere-turn.

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MMF=I*n Amp-turn

Current carrying conductor

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9

Literature survey

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OVERVIEW

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Objective• To Develop and fabricate an Electromagnetic

engine

• Testing of Engine for its power output and efficiency

• To Evaluate the Performance of Electromagnetic Engine

Methodology

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COMPONENTS AND DESCRIPTION • Cylinder

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• Piston

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• Connecting rod

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• Flywheel

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• Electromagnet

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An electromagnetic coil is formed when an insulated solid copper wire is wound around a core or form to create an inductor or electromagnet. When electricity is passed through a coil, it generates a magnetic field. One loop of wire is usually referred to as a turn or a winding. we have wound 350 turns.

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Diameter 0.065 m

Height 0.080 m

RELAY A relay is an electrically operated switch.

Current flowing through the coil of the relay creates a magnetic field which attracts a lever and changes the switch contacts.

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• Battery

• The batteries we are using is lead acid battery which has a nominal supply voltage 12 volts and 7Ah current. By series combination we get supply voltage of 36 volts.

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TIMER 555 IC

TIMER 555 IC is used to control accurate time delays for Relays to switch ON and OFF.

DESIGN CALCULATIONInput voltage = 36 V

Input current = 10A

Input Power = Voltage × Current= 36 × 10 = 360W

Force exerted by electromagnet on piston:

F1=

22

GIN AK

2

22

2

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Where, N = number of turns = 350I = Current flowing through coil = 10 AK = Permeability of free space = 4π×10-7A = Cross-sectional area of electromagnet (radius

r = 0.0325m)G = Least distance between electromagnet and

permanent magnet = 0.01md = diameter of electromagnet = 0.065 m

On substitution we getMax Force F1 = 255.40 N

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Force exerted by permanent magnet:

F2 =

B =

On substituting the value of flux density we get

F2 = 11.1 N

F = F1 + F2

= 266.48N

0

2

2AB

5.025.02)2[2 ()( ZRZDR

B ZZDr

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Torque

T = F× r

Where F = total force on piston = 266.50 N

r = crank radius = 0.01m

T = 266.50 × 0.01

Torque T = 2.665 N-m

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Mass of Flywheel

Energy stored on FlywheelE=T × ѲWhere T= torqueθ = Angle of rotation = 180C radians on substitution we getE = 6.372 JoulesAlso,E= 0.5×I×ω2

I = 0.0189 kg-m2

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60

2 TNP

I= 0.5 × m × r2

Where , m = mass of fly wheel

r = radius of fly wheel = 0.085 m

m = 2.12 kg.

Output Power:

Where,

N = speed= 200rpm

T = Torque= 2.665 N-m

On substitution,we get

P = 55.71 W27

100360

81.55

EFFICIENCY

Efficiency = Ƞ =

Ƞ = 15.51 %

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Factor of Safety of Cast Iron Frame

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22

3

bd

WLF

220302

61081.9403

F =29.9 N/mm2

Working stress,

Where L = Length of the frame in mm, W = Weight acting on the frame in Kg

b = Breadth in mm d = Depth in mm

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9.29

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Factor of Safety, FOS =

=

FOS = 4.3When Factor of Safety is greater than or equal to 1,then the Design is safe.i.e., FOS ≥ 1

4.3 > 1, hence Design is Safe.

FABRICATION AND ASSEMBLY• CYLINDER

• The cylinder developed is made of aluminum, a non-magnetic material which limits the magnetic field within the boundaries of cylinder periphery. Usage of aluminum material makes the engine lighter unlike the cast-iron cylinder used in internal combustion engine.

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width 0.075 m

length 0.075 m

height 0.1 m

Bore diameter 0.038 m

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PISTON

• The hollow piston casing is made up of non-magnetic stainless steel.

• One end of the hollow case is fitted with a powerful permanent magnet made of neodymiumiron-boron (NdFeB)

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Diameter 0.038 m

height 0.034m

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CONNECTING ROD

In a reciprocating engine, the connecting rod is used to connect the piston to the flywheel. It converts the linear motion or reciprocating motion of the piston to the circular motion of the flywheel. The material of the connecting rod is cast iron. The connecting rod used is same as that of an Internal Combustion engine without any modification

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Length 0.086m

Big end diameter 0.012m

Small end diameter 0.010m

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FLYWHEEL

• Flywheel is made up of mild steel and it is used to convert reciprocating energy into rotational energy. It regulates the engine’s rotation, making it operate at a steady speed. The diameter of the outer circle is 170mm and of the through hole at the center is 30mm

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ELECTROMAGNET

An electromagnetic coil is formed when an

insulated solid copper wire is wound around a core or form to create an electromagnet. When electricity is passed through a coil, it generates a magnetic field. One loop of wire is usually referred to as a turn or a winding. we have wound 350 turns.

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Diameter 0.065 m

Height 0.080 m

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SUPPORT FRAME

The support frame is made up of cast iron. It holds the piston and cylinder assembly with electromagnetic coil arrangement. The length, breadth and height of the stand are 600 mm. 260mm and 280mm respectively. The manufacturing process involved are cutting and welding

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Length 0.61 m

Width 0.26 m

Height 0.28 m

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ASSEMBLYThe setup is as follows:

• The electromagnetic coil is held between two fixed supports on the frame.

• Similarly the cylinder block is mounted on the fixed electromagnetic coil

• NdFeB permanent magnet is attached to the piston head by means of a strong adhesive.

• Piston is mounted inside the cylinder.• The small end diameter of the

connecting rod is fixed to a piston and the big end diameter to the flywheel.

• And the flywheel converts reciprocatory motion of piston into rotary motion.

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COST ESTIMATION

Sl. No. Name of the Parts Material Used Qty. Amount (Rs)

1 Battery - 3 2100

2 Permanent magnet

Neo Dymium –Boron 1 1000

3 Stand (Frame) Cast iron 1 1000

4 Electromagnet - 1 2000

5 Relay and Ic timer - 1 500

6 Piston Stainless steel 1 1500

7 Connecting rod Cast iron 1 600

8 Flywheel Mild steel 1 900

9 Nut and bolts Mild steel 2 20

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• Material Cost =Piston+ connecting rod + flywheel + Nuts and Bolts

= 1500 + 600 + 900+20

= Rs. 3020/-• Fabrication Cost =Rs. 2000/-

• Total cost = Component cost + Material cost + Fabrication cost = Rs.11620/ -

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TESTING

• Variation of Current with Force

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Current, amp Force, N

2 21.48

4 52.07

6 103.07

8 174.47

10 266.27

Variation of input Power with Efficiency

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Power input Efficiency

72 6.09

144 7.56

216 9.98

288 12.68

360 15.48

RESULT

The prototype of an electromagnetic engine which works on the principle of magnetism was successfully developed, fabricated and tested. Result analysis was done on the prototype. The results obtained are as follows.

• Prototype of an engine which works on the principle of magnetism was tested successfully.

• It uses electricity as its input without fuel. • The prototype creates no pollution and is eco-friendly. • Only the repulsive force between the magnet and electromagnet is

used for power generation. • Acceleration is done by controlling the timer which controls the

relay. • Maximum efficiency obtained was 15.81 %.• Maximum output power obtained was 55.81 W .

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CONCLUSION AND SCOPE FOR FUTURE DEVELOPMENT

The prototype is an idea which uses the property of an electromagnet by virtue of which it changes the polarity of its poles whenever the direction of current is changed. This variation in polarity is utilized to attract or repel the permanent magnet attached to the piston. The usage of relay and timer will limit the output of the engine. By using an ECU in the engine instead, power can be obtained on each stroke which will result in an increased output. Also, by inserting more permanent magnets in series on the piston will enhance the output of the engine. By slight modification in design and by the use of better hands the engine can be modified to generate more power, thereby increasing its efficiency, so that it can be used in commercial vehicles and other applications.

 

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Jeff Baird-

A inventor whose creation was recently featured in Popular Science magazine unveiled his latest invention Saturday. Ada area resident Jeff Baird’s newest invention is an engine that uses a technology that really isn’t new at all. Large batteries fire the magnets and the motor acts as an alternator that keeps the batteries charged continuously. The technology works like windmills except it uses magnets instead of wind.

 

 

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Peter van Blarigan-

References

• [1]Atulkumarsingh, PrabhatRanjanTripathi, Microcontrolled Electromagnetic Engine, 2011, International Conference on Advances in Electrical and Electronics Engineering (ICAEE'2011)

 • [2]J.Rithula,J.Jeyashruthi and Y Anandhi,Electric Vehicle with Zero-fuel ElectromagneticAutomobile

Engine,2013,1,2&3Department of Electrical & Electronics Engineering, Sri Sairam Engineering College, West Tambaram, Chennai, India. Volume 6, Number 4 (2013), pp. 483-486

 • [3]Shirsendu Das,An ELECTROMAGNETIC MECHANISM WHICH WORKS LIKE AN ENGINE, IJETT- Volume 4

Issue 6-June 2013

 • [4]Abil Joseph Eapen, AbyEshowVarughese, Arun T.P,Athul T.N, 2014,

ELECTROMAGNETIC ENGINE, International Journal of Research in Engineering and Technology.

 • [5]AmarnathJayaprakash, Balaji, G., Bala Subramanian, S. and Naveen, N.,STUDIES ON ELECTROMAGNETIC

ENGINE International Journal of Development Research Vol. 4, Issue, 3, pp. 519-524, March, 2014

• [6]C. Sudhakar, K. Premkumar, K.Vijith, S.Balaji,“EMISSIONLESS ENGINE BY USING ELECTRO MAGNET”, 2014

• [7]K.Mahadevan and L.Balaveera Reddy “DESIGN DATA HAND BOOK” for Mechanical Engineers, Third Edition.

• [8]Peter van Blarigan, “ADVANCED INTERNAL COMBUSTION ENGINE RESEARCH ” Proceedings of the 2000 DOE Hydrogen Program Review.

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Fabricated model photographs

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Cylinder

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Piston with Connecting rod

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Flywheel

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Electromagnet

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Relay and timer

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Battery

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Assembly

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