1st Generator Prototype

The key component in our project is the generator. This forms the basis of generating the required power to aid an existing charging system in charging a vehicles battery. At this point, we have constructed a prototype generator to simulate current and voltage generation.

Prototype generator components include:   
 

1.   0.25mm (d) of enamel copper wire

2.   40mm (d) x 10mm (h) Neodymium magnet

3.   50mm (inner d) x 80mm (h) pvc tube

4.   Single phase 1.0A bridge rectifier

Initially, the coil was wound 300 turns (N) and each end connected to the bridge rectifier. The rectifier output terminals (-) and (+)  are connected by copper wire which are to be later used as testing probes.

On 31 November 2011, the first generator bench test was conducted. A computer oscilloscope was used to capture the peak output voltage created by the generator. It was found that the induced magnetic field generates small voltage. A peak voltage reading of 0.962V was taken at an oscillation frequency of approximately ±1Hz,and a maximum voltage of 1.169 V at ±1.5Hz oscillation . It was also noted that with the current setup, the generator was hardly able to charge the energy accumulator (3900μF capacitor).

Chart-1: Peak Voltage= 0.962 V @ 1Hz

Chart-2: Peak Voltage=1.169 V @ 1.5Hz

The test results from the first prototype proved that the frequency of the permanent magnet oscillation which cuts the magnetic fields is a big contributing factor in generating peak voltages. Simultaneously, it shows that the generator does not generate enough amperage to charge the capacitor. Hence, it is necessary to improve the design of the prototype.

We concluded that the current and peak voltage generated are too small for the project objective. We need to amplify the generator output, which requires an improvement of certain aspects of the generator design.

Progress Presentation

Today, we presented to our lecturers all our work to date. The reasoning behind our presentation is to help keep us on target. It was a wake up call as it was my worst presentation that I have ever participated in. Not only was I late, I was also ill prepared. I felt like a robot without a brain and when it came time for the lecturers to provide their feedback, lets just say we had a lot of constructive criticism. 

If we are to move on from today, we need to pick up the pace, put our heads together and get the work done. I hope to meet with Azizi in the holidays to complete the majority of the practical work done so that we may begin with our written report.

Circuit Operation

During normal vehicle operation, the suspension oscillations will cause the generator to jounce up and down in a vertical motion with the vehicles unsprung mass due to the generator being fixed to the vehicles chassis. This causes the rotor to simultaneously pulsate in and out of the coil windings, thus cutting through the lines of magnetic flux and inducing a current and AC voltage in the copper wire (stator). 

From the stator, current conventionally flows to the bridge rectifier, where the AC voltage is converted to workable DC voltage. The output voltage then flows to the capacitor and begins to charge it. Once the peak charge threshold is met then the current is redirected to charge the battery.

The Generator Componentry

The generator consists of two major components, the rotor and the stator. The rotor is the oscillating moving part while the stator is the static section. The rotor and the stator are separated by a small air gap to allow the oscillating movement between the rotor and stator to take place.

Figure - 1: Generator componentry

The permanent magnet is fixed to the linkage rod and acts as a rotor. Meanwhile the coil windings and the steel plate play the role of a stator. In order to make the magnetic circuit as efficient as possible, the magnetic field passing through the coil must be maximized. To allow for this the coil windings were selected from a  material type with a low permeability.

Figure - 2: The generator schematic diagram

At the heart of the generator is the accumulator, which filters the generated output voltage through a rectifier and  a capacitor. The battery would be connected in parallel with the capacitor.

The Generator Circuit

Figure - 1: Generator charging circuit wiring diagram

Figure - 2: Generator schematic

Charging Circuit Requirements

A charging system must meet the following criteria while the engine is still running:

- Supply the current demands made up by all loads

- Supply whatever charge current the battery demands

- Operate at idle speed

- Supply constant voltage under all conditions

- Have an efficient power to weight ratio

- Be reliable, quiet, and have resistance to contamination

- Require low maintenance

- Provide an indication of correct operation

Researching Charging Circuits

A charging system performs several functions. These include:

1. It recharges the battery after engine cranking or after the use of electrical accessories with the engine turned off.

2. It supplies all of the vehicles electricity when the engine is running.

3. It must alter its output to meet varying electrical loads.

4. It provides a voltage output slightly higher than battery voltage.

Components:

1. Generator- Utilizes kinetic energy to generate electricity.

2. Voltage regulator- An electrical device which is used to control the current and output voltage of a generator.

3. Charge Indicator- A warning lamp, ammeter or voltmeter to inform the driver of the charging system condition.

4. Wiring Harness- Charging system wiring that connects system components.

5. Battery- Provides current

Final Contract Signed

We met with our lecturers today to present our final contract for approval. We have been working towards this moment for quite sometime now, and we began to realise that any rejection would be a step backwards for us. It would also mean that we would fall behind schedule, which would make it a more difficult task for us to meet our deadlines. 

Luckily, we were met with positive feedback and our project contract was finally approved. This meant that we were now able to progress to the next stages of our project and begin the time consuming task of in-depth research of our topic.

The Final Contract

Contract of Technology Project APPT6112

Project Name:
Harnessing the Wasted Energy in a Vehicle
Project brief:
Problem: Wasted kinetic energy through suspension movement in motor vehicles. Energy used up to drive the alternator contributes to engine inefficiency. The fact that modern gasoline engines have an average efficiency of about 18% to 20% when used to propel a vehicle, due to wasted energy. Solution: The project is to harness the wasted kinetic energy on vehicle suspension systems with the use of a ferromagnetic generator for power regeneration. At the same time it will reduce the existing engine work to turn the alternator, as well as energy loses through alternator heat dissipation. The generator will be attached to the shock absorber as a bolt on kit. To complement this system we will also design and construct a charging and battery management control circuit as a control module for the system. The generator will be constructed using copper wound on PVC pipe as a stator, and a permanent magnet as a rotor. The module will consist of several electronic components and Ic’s.
Agreed Outcomes:
To design, construct and analyze a supplementary charging system using a ferromagnetic generator. To design and construct a control module to manage the supplementary power generator system. To identify the overall charging rate produced by the ferromagnetic generator. To study the engine efficiency gained when incorporating the new system.
Names and ID	Gmail and blogger address		Signature	Date
Azizi Abdullah	Gmail	Azizi.abd@gmail.com
ID: 1375797	Blogger	http://azizi-abdullah.blogspot.com/
Fiva Faaofo	Gmail	Fiva.faaofo@gmail.com
ID:1352640	Blogger	http://fivasblog.blogspot.com
Technical Advisor/s	Prabhat Chand
	Lixin Zeng
Course Co-ordinator	Jone Tawaketini

Refining the Project

After presenting our proposed contract to Prabhat, we dicussed and came to an agreement that maybe our topic and objectives were a bit minded as our focus was solely on charging electric vehicle batteries. Prabhat then suggested that we go mainstream and to put the focus on today's vehicles which still incorporate the traditional internal combustion engine. Not only that but he challenged us to rethink our objectives and to come to a realisation about what we really would like to achieve from doing this project. 


We currently back to the board with this as we try to revise our contract to allow the topic to be broadened rather than a closed concept. We hope to get this contract approved and sign as soon as possible so that we may progress to the next stage.

Harnessing Energy

Today, we had  a meeting with our technical advisor Prabhat Chand to present the idea for our project. Our concept is to design a regenerative charging system which harnesses the kinetic energy created by suspension oscillations to effectively charge a  12v auxiliary battery for an electric vehicle. This battery will be independent from the main drive module and will be used to power all of the auxiliaries of an electric vehicle. The system will also feature a AC generator and a converter. As result we expect to increase the main battery module capacity, therefore increasing vehicle mileage. We felt that this was an important topic seeing as the main issue with electric vehicles is their limited mileage, due to the limited battery capacity.

After discussing the topic, Prabhat suggested that we generalise our concept idea and target all types of vehicles rather than limiting the application to just electric vehicles. Furthermore he encouraged us to think critically and to approach this topic from an energy harnessing perspective rather than just generating electricity. We also went on to discuss the  construction of the generator, the charging circuit, its components and various tests that may need to be conducted to back up our research and findings.

Generally, we are happy with the new concept and approach that we have gained from the discussion. Now, we need  to research a bit more about energy harnessing and rewrite our contract. So far, our progress is going well as planned and  we hope to get the contract signed by next week.

Proposed Contract

Contract of Technology Project APPT6112

Project Name:
Regenerative Energy and Supplementary Power Supply System
Project brief:
Problem: Limited operating mileage for Electric Vehicles (EV) due to limitation of battery capacity. Power consumed by other electrical components/auxiliaries (e.g. headlamp, indicator, brake light etc.) drain battery power and reduce the vehicle mileage. Solution: The project is to design, construct and analyze the ferromagnetic generator for energy regeneration. The generator will be attached to the shock absorber as a bolt on kit. The system will also include a separate 12V power supply. To complement this system we will also design and construct a charging and battery management control circuit as a control module for the system. The generator will be constructed using coper wound on PVC pipe as a stator and permanent magnet as a rotor. The module will consist of several electronic components and Ics.
Agreed Outcomes:
To design a supplement charging system using additional ferromagnetic generator. To design additional battery management systems to control the usage of the 12V supplementary power system. To identify the charging rate produced by each ferromagnetic generator. To investigate electrical energy consumed by 12V electrical components on EV’s. To find out how much additional mileage can be gained by an EV with the proposed supplementary charging system. To investigate the average mileage per Specific energy consumed by EV’s.
Names and ID	Gmail and blogger address		Signature	Date
Azizi Abdullah	Gmail	Azizi.abd@gmail.com
ID: 1375797	Blogger	http://azizi-abdullah.blogspot.com/
Fiva Faaofo	Gmail	Fiva.faaofo@gmail.com
ID:1352640	Blogger	http://fivasblog.blogspot.com
	Gmail
ID:	Blogger
Technical Advisor/s	Prabhat Chand
	Lixin Zeng
Course Co-ordinator

Researching Charging Circuits

In order to supply a vehicle with the power required for the starter motor, for ignition and fuel injection systems, for the ECU's to control electronic equipment, for lighting, and for safety and convenience electronics. Vehicles need a generator to act as their reliable source of energy. This energy must be readily available, at any time day or night.

While the engine is off, the battery is the vehicles energy store, and while the engine is running the generator becomes the on-board power plant. When the generator output is greater than the that needed by the vehicle, it sends the excess current to the battery to maintain the battery's state of charge. It is the generators task to supply energy to all the vehicles current consuming loads and systems.

Source: www.familycar.com

In order for the vehicles electrical system to remain reliable and trouble free in operation. It is important that the generator output, battery capacity, and starter power requirements, together with all other electrical loads, are closely matched to each other.

Topic Selection: Regenerative Shock Absorber

After further research and rigorous discussion, we have decided to develop a regenerative shock absorber system. This system will act as a generator to charge a 12V auxiliary battery, which will be used to power the auxiliaries of an electric vehicle. We also want to incorporate a circuit to control this charging device.

Now we must do some research and find what type or arrangement of charging circuit will be suitable for this system. Whatever the circuit design, it meet the following requirements:


- Stimulate maximum voltage and current output
- Feature circuit protection
- Developed using theoretical knowledge of charging systems

Brainstorming Ideas

Today, we brainstormed possible ideas for our project. Possible ideas include:


- Alternative fuel source
- Long life car battery
- Fuel magnetization
- Variable compression engine
- Harnessing wasted energy 


We decided our primary concept is to design a regenerative system which generates electricity from wasted kinetic energy of a vehicle. The key question is how would we incorporate such a system into a vehicle design? We discussed retro-fitting the system into areas which would generate a considerable amount of kinetic energy. Possible locations for optimum energy harnessing include:

-The hub assembly/wheel bearing

-Drive shaft assembly

-C.V joint

-Shock Absorber

-Suspension

Fuel-less Energy Concept

We began the day with Lixin and Naranjan, discussing possible topics for our technology project.  I found this very helpful as I lacked ideas and sense of direction. Having the tutors giving us examples helped steer me in the right direction.

Later, we were encouraged to converse with our peers to help select groups for the technology project. After careful consideration, Azizi and myself opted to form a group. I was happy with this decision as I have previously worked with Azizi and I feel we make a great team.

From here, as a group we shared our ideas to date. After further discussion, we came to a mutual agreement, and we decided on the idea of utilizing kinetic energy to possibly charge an additional 12V auxiliary battery in a electric vehicle. Ultimately, the main idea behind this concept is to use this auxiliary battery to supplement power to all the auxiliary devices. As a result, there will be less load on the main battery therefore increasing overall vehicle mileage.

The above video shows the inspiration behind our concept. It consists of a permanent magnet, coil windings, and a soft iron core to form an ac generator. It is a basic concept but an effective one nonetheless. The challenge is deciding how we will incorporate this concept into our idea, and how can we make it our own.

First Day (Technology Project)

Today is the first session of the Technology Project A class. We were introduced to the tutors, namely, Lixin, Naranjan, Gerry, and Anura. Each assisted in giving an introduction to the course, course outlines, and assessment requirements. The assessment weightings and deadlines were also briefly discussed, aswell as the mention of the importance of project management in this project.

The course at first glance, seems very self directed, and so alot of time and team work is required if we are to be successful. The issue arises in finding the right team players, who are committed to participating in our group activities, and who will work together effectively to complete the assessment tasks and objectives on time.

We leave today knowing the tasks we have ahead, and what is required of us in order to do well in this course. There is no doubt in my mind that our experience in our recent project management course will play a big role if  we are to to do well, and so we must draw from past experiences to help us achieve all course objectives. In the end, I can see how this course can go a long way in helping us later in the future, when we enter into industry.