Mukt Shabd Journal ISSN NO: 2347-3150

Design and Analysis of Electricity Generation using Contactless Magnetic Coupling

Aniket Madwe1, Abhinav Deshmukh2, Nachiket Dhange3, Rutuja Godse4, K. R. Jagtap5

Mechanical Engineering Department, Sinhgad Institute of Technology and Science, Savitribai Phule
Pune University, Pune, Maharashtra-411041, India

[email protected]
[email protected]
[email protected]
[email protected]
[email protected]

Abstract

The renewable energy sources are rapidly depleting across the planet. There is a continuous need of
new methods and ideas of generating energy without harming the environment. This paper aims to
produce electricity in railway bogies using non-contact magnetic coupling mounted on the axles of
the bogies. The main focus of the model was to generate electricity using a magnetic coupling. The
torque was transmitted from the axle to the generator shaft without any physical contact, thus
reduced the friction losses in currently being used mechanical couplings for torque transmission.
Computer aided modeling (CAD) of the system is done using CATIA software. The model was
validated for its design feasibility and structural analysis is done using Ansys software.

Keywords: Electricity generation, Magnetic coupling, Non-conventional energy, Finite Element

Analysis (FEA)

I. INTRODUCTION
The planet is rapidly running out of conventional fuels, and non-conventional sources of energy are
becoming our future. Natural resources like wind, tides, solar, biomass, etc., generate energy which is
known as Non-conventional resources. These are pollution free and hence we can use these to
produce a clean form of energy without any wastage. There is a need to secure the energy supply for
the future since the prices of gas and oil keep rising with each passing day. We need to use more and
more renewable sources of energy.

In India, the major transportation system is railways which consume high-grade energy like
electricity. Most of the system in railways works on electricity, which need a continuous supply of
power. To deal with this demand we were proposing an electricity generation system for railway
bogies which offer a continuous supply of electricity for all required purposes. The main goal to build
such a system was to replace the conventional methods of electricity production in trains and
introduced a non-conventional and eco-friendly way of electricity production which will be both
continuous and free of cost.

Electric Power Generation using Contact-less Magnetic Coupling was a system proposed to generate
electricity in railway coaches. The electricity produced by this system is free-energy and the method
used was very eco-friendly. The system was driven by the axle of the coach using a non-contact
magnetic coupling. An electric motor, which drives the primary or input shaft, demonstrates the
rotation of an axle. The torque and motion transmit by a magnetic coupling to a secondary shaft. The

Volume IX, Issue VI, JUNE/2020 850

Mukt Shabd Journal ISSN NO: 2347-3150

magnetic coupling works on the principle of attraction and repulsion of magnets. The secondary shaft
transmitted the torque to the generator shaft through a gear mechanism. It was not possible to directly
connect the generator shaft to the magnetic coupling hence the gear mechanism used for this purpose.

Yi-Chang Wu and Chih-Wen Wang [1] investigated the magnetic field and the transmitted torque of
an external magnetic gear set with rectangular magnets by using the current sheet model and finite
element analysis (FEA). The analytical expression of torque transmitted is compared with the
magnetic material properties and geometric dimension of magnetic gear mechanism graphically.

T. Meenakshi et al. [2] proposes a novel technology to convert rotational energy into electrical using
a technique called repulsion magnetic technique. The system uses permanent magnet to produce
repulsion and this repulsive force produces a torque which drives a direct current (DC) generator and
matlab Simulink model of a single-phase 2kVA UPS system based voltage controlled. The repulsive
magnet disc consists of two magnetic discs of which one is mounted on rotating machine and other is
mounted on generator shaft. The power output from the direct current (DC) generator is fed to
uninterrupted power supply (UPS).

S. R. Trout [3] investigated the permanents magnets and studied thermal properties of the same. He
examined four families of permanent magnets namely ferrite, alnico, Samarium-cobalt, neodymium
iron boron along with their properties such as remanance, curie temperature, Intrinsic coercive field,
etc. he proposed a new definition for the maximum operating temperature and advised on which
properties are most important in various design situations.

S. M. Hatturkar [4] aims toward generating electric power through non-conventional method by train
running on a railway track.The main aim of the concept is to utilize the train crossing time on a
railway track. The power is produced by the railway track power generation equipment. The principal
of operation is a flat strip held on the axle of a train which will be touching the roller on the track,
and the roller starts rotating according to the rotational energy transformation features generating
electricity through generator.

V. Thirumalairaj et al. [5] proposes a technology to produce electrical energy using repulsion magnet
technique. The system uses magnetic disc made up of plastic which contains a number of permanent
magnets arranged on a circumferential portion of the magnetic disc. Magnets used are Neodymium.
The magnetic disc and larger size driver plastic gear are connected by the shaft, rotates freely with the
help of bearing which is rigidly fixed with stand. The same polarity of magnet is placed on the surface
of the motor shaft which is placed near the magnetic disc. The output from the generator is increases
by the voltage booster.

A. Working Principle of Magnetic Coupling

The working principle of magnetic coupling is based on the theory of attraction and repulsion of north
and south poles of a magnet. The magnetic coupling is used to transfer torque and motion from one
shaft to another in axial direction. There is a maximum of 10mm gap between the two discs of
coupling on which north and south pole magnets are mounted alternately. When the driver shaft
rotates the magnetic coupling tends to pull the other shaft in the same direction, resulting in rotation
of the driven shaft. Magnetic coupling is a contactless coupling which does not need any physical
contact to transmit torque or motion. This contactless motion transmission provides a friction free and
leak proof environment which is very useful.

Volume IX, Issue VI, JUNE/2020 851

Mukt Shabd Journal ISSN NO: 2347-3150

Figure 1: Parallel axis magnetic gears [3]

B. Working of Proposed Model

The system works on the input provided by a 12V battery to a 12V and 100 RPM wiper motor which
drives the input shaft on which a wheel and magnetic coupling are mounted. The wheel is mounted so
as to demonstrate the rotation of railway wheel and also it stores the inertial energy from the
rotational motion. The input shaft is mounted on the frame using bearings at the two ends. The output
shaft is perpendicular to the input shaft which mounted using bearings on the frame and the other end
of the output shaft is connected to the generator.

The magnetic coupling is two discs attached to the input and output shaft. On the outer periphery of
the discs permanent magnets are attached in an alternate manner, i.e., north and south poles
alternately. The coupling disc on the input shaft rotates and implies torque on the other disc of
coupling based on attraction and repulsion. Thus the output shaft rotates without any physical contact
between the shaft or the magnetic coupling. This provides a frictionless torque and motion transfer
without any mechanical contact.

The output shaft drives the generator which in turn produces electricity. The electricity, thus
generated can be stored in the batteries and can be used as per requirement. The generator and battery
are fitted to the frame using attachments.

II. CALCULATIONS

A. Selection of Pulley and V- Belt.

Selection of pulley is done on the basis of power and input speed.

Power = 0.036 KW
Input Speed = 100 RPM
Centre Distance = 400 mm

Minimum pulley pitch diameter (d) = 75 mm

Volume IX, Issue VI, JUNE/2020 852

Mukt Shabd Journal ISSN NO: 2347-3150

Assuming speed ratio (i) = 2

𝐷 𝑛
∴i=𝑑 =𝑁

∴ D = 150 mm

V belt is selected instead of flat belt as the chance of slip is less.

𝜋 (𝐷−𝑑)2
Pitch Length of V belt (L) = 2𝐶 + 2 (𝐷 + 𝑑) + 4𝐶
[7]

L = 1156.94 mm

Selecting the corresponding length from the design data book,

∴ L = 1204 mm

Nominal inside length = 1168 mm

Correcting the center distance (C) = 𝐴 + √𝐴2 − 𝐵 [6]

𝐿 (𝐷+𝑑)
Where, A = 4 − 𝜋 × 8

(𝐷−𝑑)2
B=
8

∴ C = 423.62 mm ≌ 425 mm

Number of belts required for a given application is calculated by following relation; [6]

𝑃×𝐹𝑎
𝑛= 𝑃𝑟×𝐹𝑑×𝐹𝑐

Where,
n = number of belts
P = drive power to be transmitted (KW)
Fa = correction factor for industrial service
Pr = power rating of single v-belt
Fc = correction factor for belt length
Fd = correction for arc of contact

Fa = 1.1 [6]

Fc = 0.92 [6]

Volume IX, Issue VI, JUNE/2020 853

Mukt Shabd Journal ISSN NO: 2347-3150

𝜋𝐷𝑁
Velocity of smaller pulley (V) = 60

∴ V = 0.392 m/s

Pr= 0.13, Corresponding to the velocity

D−d
Arc of contact =180° − 60° × C
[7]

Ө =169.37º

Fd = 0.78, Corresponding to the velocity

0.036×1.1
∴ No. of belts (𝑛) = 0.13×0.78×0.92
= 0.42 ≌ 1

From this, A-46 size belt is selected from manufacturer’s catalogue.

B. Design of Shaft

Shafts are subjected to axial tensile force, bending moment or torsional moment or their
combinations. Most of the shafts are subjected to combine and torsional moments. The design of shaft
consists of determining the correct shaft diameter from strength and rigidity considerations.

1) Calculating the tension on pulley on input shaft.

2𝜋𝑁𝑇
From general equation of power, 𝑃 = 60

T = 3.43 N.m

Equivalent torque transmitted by pulley = 𝑖 × 𝑇

= 6.86N.m

Equivalent torque is given by, Te = (T1 − T2) × R

𝑇1
Also, 𝑇2
= 𝑒 µӨ

Where,
µ = 0.297
𝐷−𝑑
Ө = 𝜋 + 2 sin−1 ( ) = 3.49 rad.
2𝐶

𝑇1
∴ = 2.819
𝑇2

Volume IX, Issue VI, JUNE/2020 854

Mukt Shabd Journal ISSN NO: 2347-3150

∴ T1 = 141.75 N
∴ T2 = 50.25 N

2) Calculating the diameter of input shaft for combine bending and twisting.

Material selected for the shaft is AISI 1118 having following properties
Sut = 525 MPa
Syt = 315 MPa
FOS = 7.5

 Shear force diagram and bending moment diagram

Shear force diagram (SFD) & Bending moment diagram (BMD) is calculated by using MD solid 4.0
software.

Figure 2: Schematic diagram showing SFD and BMD of vertical loading diagram of input shaft using
MD Solid software

Figure 3: Schematic diagram showing SFD and BMD of horizontal loading diagram of input shaft
using MD Solid software

Volume IX, Issue VI, JUNE/2020 855

Mukt Shabd Journal ISSN NO: 2347-3150

 According to maximum shear stress theory, [7]

16
𝜏 = 𝜋𝑑3 × √(𝑀𝑏)2 + (𝑀𝑡)2

Where,
Mb = Maximum bending moment on the shaft
Mt = Maximum torque acting on the shaft

Value of Mb = 4821.25 N.mm ( From Fig 2)

And Mt = 6875.49 N.mm

∴ d = 12.67 mm
∴ d = 16 mm is selected

As there is less magnitude of load and torque acting on the output shaft than the input shaft, the
diameter of output shaft selected is also 16 mm.

III. RESULT AND DISCUSSION

Details of the analysis:

 Product Version: ANSYS 18.2

 Specimen geometry: 16 mm diameter and 605 mm length (input shaft) 16 mm diameter and
410 mm length (output shaft)
 Material: Carbon Steel
 Mesh element size: 3mm
 Analysis type: 3D
 Solver target: Mechanical APDL
 Solutions obtained:
1) Y-axis directional deformation.
2) Equivalent Stress distribution along the specimen.

A. Analysis of input shaft

Figure 4: Total Deformation of input shaft

Volume IX, Issue VI, JUNE/2020 856

Mukt Shabd Journal ISSN NO: 2347-3150

 From figure 4 it is observed that the total deformation of the input shaft is equivalent to zero, this
means the input shaft sustain all the loads and torque without any deformation. The red color shows
the maximum possible deformation.

Figure 5: Equivalent Stress distribution on input shaft

 Figure 5 shows that the maximum stress is directed over the keyway. The maximum and minimum
values of induced stresses are 87.909 N/mm2 & 0.0014 N/mm2.

B. Analysis of output shaft

Figure 6: Total deformation of output shaft

Volume IX, Issue VI, JUNE/2020 857

Mukt Shabd Journal ISSN NO: 2347-3150

 From figure 6 the deformation is observed at one of the free ends only. The value of
deformation is 0.0627mm which is negligible.

Figure 7: Equivalent Stress distribution on output shaft

 It is observed from figure 7 that the maximum stress is directed over the keyway. The
maximum and minimum values of induced stresses are 22.025 N/mm2 & 0.00010 N/mm2.
 The output shaft undergoes into minimum loading condition than the input shaft therefore the
observed values of stress induced is minimum.

IV. CONCLUSION

In this paper the study and FEA analysis of shaft is examined. FEA analysis results were used to
validate the analytically obtained results. The analysis is done on 16mm diameter shaft which easily
withstands all the forces and torque acting on it without any deformation. Therefore, it is concluded
that the design is safe.

REFERENCES

[1] Yi-Chang Wu and Chih-Wen Wang, “Transmitted Torque Analysis of a Magnetic Gear
Mechanism with Rectangular Magnets”, Applied Mathematics and International Journal (2015),
1059-1065

[2] T. Meenakshi, S. Sujith Kumar, S. Suganya,“Electricity Generation by Employing Repulsion

Magnetic Technique in Rotating Machines”, IOSR Journal of Electrical and Electronics Engineering
(2014), 47-52.

Volume IX, Issue VI, JUNE/2020 858

Mukt Shabd Journal ISSN NO: 2347-3150

[3] S. R. Trout, “Material Selection of Permanent Magnets, Considering Thermal Properties

Correctly”, Electric Manufacturing and Coil Winding Conference, Cincinnati, Ohio, USA (2001) 01-
06

[4] S. M. Hatturkar, “Electric Power Generation Using Railway Track”, International Journal for
Reasearch in Applied Science & Engineering Technology (2017), 141-151

[5] V. Thirumalairaj, A. Vembathu Rajesh, R. Radhakrishnan, M. Pradeep, J.

ChakravarthySamyDurai, “ Electric Power Generation by Using Magnetic Repulsive Force”,
International Journal for Reasearch in Science, Engineering & Technology (2017), 21432-21437

[6] PSG TECH, DESIGN DATA BOOK, M/s Kalaikathir Achchagam, Coimbatore (2010), 7.58-7.70

[7] V. B. Bhandari, Design of Machine Elements,Mc Graw Hill Education, Chennai, 4th edition
(2017), 517-528

Volume IX, Issue VI, JUNE/2020 859