Pedal Powered Electricity Generator

By
Michael Mazgaonkar, Paryavaran Suraksha Samiti, India, [email protected]
Ronnie Sabavalla, Himalaya Machinary Ltd., India, [email protected]
Ravi Kuchimanchi, Association of Indias Development, India, [email protected]
India

July 2001

Abstract
Pedal Powered Generators have been of interest at many places where no other alternative
electricity generator has been viable. While using pedal power is not a new concept in itself, it
has not been successfully used on a wider scale. There are a lot of schools in rural India, which
are residential and are not grid connected. A pedal power generator with a lighting system was
developed for such schools and tested. It provides 40 minutes of lighting for 10 minutes of
pedaling. Currently about 10 such lighting systems are in use all over India and more are being
shipped.

Introduction
India is the second most populous nation in the world. Like many other countries where
agriculture is the main activity, biomass and other non-commercial fuels constitute around 40
percent of energy requirements in India. Around 85.49 percent of Indian villages are electrified. 1
Many will not be electrified for considerable time. Many schools in rural India are residential
schools (including primary schools). Children and staff live within the school campus. Evening
hours is the time when the students do homework and other reading activities. Most of the
schools use kerosene lamps for lighting during evening hours. This is an inefficient way of
lighting and does not provide enough light anyway. There are not many other ways of lighting
left for these schools, as generators are too expensive and difficult to maintain. Most of the times
fuel is too far away and difficult to carry over terrains, and often there are no roads to reach the
schools. These schools typically need light for about four hours every evening and about one-two
hours every mornings. The light needed is mainly for reading. These schools have between 40 to
100 children. They also have 3 or 4 staff families. Civil society organisations often work in areas
that have no electricity. They hold meetings and programmes where electricity is needed for
talks or for audio-visual equipment or for other miscellaneous purposes.
A totally different approach was taken to design the machine. The machine was designed and
fabricated by the manufacturing facility itself and field testing was done by end users themselves
and not by 'engineers' or 'scientists'. The Locally available parts were used to make the machine
as far as possible and the product was continuously tested with the users directly

Why Pedal Power

We explored a lot of different ways of lighting the schoolrooms. The requirements were quite
minimal. Only lighting was the basic need. We considered solar photovoltaic, pressure kerosene
lamps, liquid petroleum gas fired mantle lamps etc. Ideal would have been the photovoltaic
system but it is prohibitively expensive for a common school in India. Therefore we decided to
develop a pedal power generator for battery charging.
Pedal power by itself is not a new concept but is not widely used. The basic idea was to pedal at
a comfortable speed and still generate enough power to make it worthwhile. We felt a ratio of 1:3
to 1:5 of pedalling time to lighting time would be encouraging enough to use this way of
lighting. And we felt that this could be achieved by using compact fluorescent lamps.

First Prototype
The first prototype was developed using
a car alternator. A used 40 Amp car
alternator was used. The speed needed to
get an output of 6 amps was over 90 rpm
(at pedals). It was felt after use for about
a month that this speed was pretty high
and could not be maintained. A reclining
chair was used for sitting. Therefore
other design changes were considered.
Limitations were found to be the design
of generator and lighting system.
Photo on the right shows the first model.

Second Prototype
The second prototype was developed
using a reclining chair but a low rpm DC
motor that was originally developed for
an electric bicycle. A 15-ampere diode
was connected so that the battery would
not drive the motor when the pedaling
stopped. Pedalling speed required to
achieve 6 amps output was brought down
to 70 rpm. The frame was made of mild
steel angles and square channels. A 40
Amp-hour battery was used to store the
electricity. Two 11-watt compact
fluorescent lamps were used for lighting.
This model was installed in the Narmada
valley and used for a year and feedback
obtained. The photo on the right shows
the second prototype.

The reclining chair was not found to be most appropriate because it did not permit totally
free movement of the legs.

Students also found the load on legs irregular during pedalling, which in turn made
people tired quicker.

An indicator for battery state of charge was also felt necessary.

Another feedback was that if the pedalling speed was reduced further then people could
pedal longer.

Third Model
A Third model was made to include all the feedback
received for the second prototype. The seat was changed
to a standard bicycle seat and basic frame of a bicycle
was used to manufacture the machine. An LED bar
indicator and an ampere metre were added for state of
battery and rate of charging indicator respectively. The
ratios were changed so that pedalling speed was brought
down to 40-60 rpm. Various experiments were done
with varying sizes of flywheels and finally a flywheel
was attached on the generator to balance the irregularity
of pedalling force.
4

The above photo shows a close up of the generator and drive pulley assembly, flywheel was
removed for better clarity:
Stepping-up of input pedal speed is in two stages, as mentioned earlier. A toothed belt drives the
generator with 77:15 ratio pulleys. The chain stage has 16 and 44 teeth ratio, so that the overall
speed step-up would be 5.133 X 2.75 = 14.12. At the chain stage (pedalling), the two sprocket
wheels combination (in place of 16:44) can be varied as follows: 16:60 or 18:60 or 18:80 or
16:80 etc. These are readily available sizes in the open market in India. Other sizes would have
to be custom manufactured. The 80 tooth is custom manufactured.
A brief description of parts is given in Annex 1 on page 7.

Conclusions
This is a useful machine at places where many people gather and stay together (meetings,
residential schools). It is easy to maintain and make. The cost is around Rs 9,500 total, inclusive
of battery (or about US $ 200).

Challenges
1. A charge controller to prevent overcharging and overuse of battery needs to be added,
especially because the battery is the most expensive single part of the machine.
2. Variable speed drives would be an advantage where people of different age groups use the
machines.
3. In the long run, alternative energy storage solutions would need to be designed because
batteries are not the right solution, especially since they use toxic substances. Novel ways of
energy storage need to be thought, without losing too much energy in transformation.

Acknowledgements
Ravi Kuchimanchi and Venkatesh R. Iyer of Association of India's Development originally
conceptualized the project and organised funding development as well as testing of the device.
Mandar Bhedasgaonkar worked on the first model under the supervision of Prof. V. P. Bapat of
Industrial Design Centre, I. I. T. Mumbai, India. Venkatesh and Ravi guided the first model as
well. Ronnie Sabavalla designed the final machine and Rashron Energy and Auto Ltd provided
all the manufacturing facility and materials for the device and withstood all the testing and trials
of various parts. Ravi Kuchimanchi provided the main inputs design and testing of the flywheel.
Ravi Kuchimanchi also did most of the field testing and provided feedback. Michael
Mazgaonkar worked closely on the feedback from end-users and helped establish contact
between the various interested people as well as the experimented with matching different kinds
of lighting systems to the battery.
1. Michael Mazgaonkar
Juna Mozda
Dediapada 393 040
Narmada, INDIA
[email protected]
2. Ronnie Sabavalla
Rashron Energy and Auto Ltd
608 GIDC, Makarpura
Baroda 390 010
Phone: 91-265-643450
[email protected]
www.ecozen.com
3. Ravi Kuchimanchi
Association of India's Development, India
C-7 Banganga Co-op Society
Station Road
Govandi
Mumbai
Phone: 91-22-556 6703
[email protected]
www.aidindia.org

Annexure 1
List of Major Components and brief descriptions
Bicycle Frame Old Bicycle frames are recycled to make the basic frame of the machine.
Seating arrangement and rear wheel fork is kept as is, so are the pedals, rest is
cut away and a basic smithy shop is used to make the machine.
Generator
A 12 V DC, 10 Amp, four pole permanent magnet motor is used.
Drive Train
First step-up is by a normal bicycle chain and freewheel drive.
Second step-up is achieved by toothed pulley and matching belt.
Battery
Usually a 12 V, 40 Amp-hour tubular lead-acid battery is used.
Indicators
An LED bar level indicator with colour coded LEDs is used to indicate level
of charge of battery.
A centre zero ammeter (-8A-0-+8A) is used to display charging rate.
Protection
A 20 Amp diode is used to protect prevent current flowing to the battery
when pedalling is stopped
A 20 Amp fuse is used to prevent shorting of the battery terminals

Yearly Review, Central Electricity Authority, Ministry of Power, Government of India, New Delhi,
www.cea.nic.in/opt3_tbl67.htm