UNIVERSITY INSTITUE OF ENGINEERING AND TECHNOLOGY

KURUKSHETRA UNIVERSITY

KURUKSHETRA

Report
On
TREADMILL ELECTRICITY GENERATOR

Under the guidance of:

Dr. Vishal Ahlawat
Assistant Professor
Mechanical Engineering Department, UIET Kurukshetra.

Submitted By:
Darshna (251804017) Jayant (251804026)
Sumeet (251804052) Himanshu (251804021)

Submitted to
MECHANICAL ENGINEERING DEPARTMENT
UIET, KURUKSHETRA
1. TREADMILL ELECTRICITY GENERATOR

1.1 Introduction

Everybody knows that exercise is good for health. No one can ignore the health benefits
of regular exercise and physical activity regardless of age, sex or physical ability. There
are many advantages of exercise. Some benefits are as below:

1. Exercise controls the weight.

2. Exercise decreases the risk of cardiovascular diseases.
3. Exercise stimulates various brain chemicals, which can leave us feeling happier and
relaxed. Exercise also makes our appearance better resulting boost in our
confidence.
4. Regular exercise improves the strength of our muscles and boosts our endurance.
Exercise also delivers oxygen and nutrients to the tissues and helps in efficient
working of cardiovascular system.
5. Exercise is helpful in fall asleep faster and deeper the sleep.
6. Exercise helps in connecting with friends and family members in a fun social
setting.

Most of the people do exercise worldwide. Different types of machines are used for
exercise. Many exercise machines are operated manually. In manual exercise machines,
muscle power goes waste during exercise. The power which otherwise goes waste
during exercise may be used by converting it into any other form of energy. With the
technological advancement worldwide, demand of energy is continuously increasing.
The power generation is also increasing and most of the energy generation plants are
using fossil fuels which bring up many adverse effects which are as below:

1. The available quantity of fossil fuel is fixed and there depletion in their available
quantity and they will be exhausted at sometime or other.
2. The fossil fuels are burnt to produce electricity resulting environmental
pollution and climate change.
3. Global warming is occurring due to climate change.

In view of the above facts there is a need of alternative methods of power generation.
Inventions are going on worldwide for generating power through alternative methods.
Most of the people do exercise worldwide. The electricity may be produced by using
 manual exercise machines integrated with Electricity Generators. In this way manual
power may be used to generate electricity during exercise and we can overcome the
above-mentioned problems up to some extent. Different types of exercise machines are
used for exercise. In conventional manual treadmill human effort goes waste during the
exercise.

1.2 Obesity

A solution that can address this great challenge is the use of Human Power that is, using
muscular strength to power engineered applications. The main source of energy is that
metabolized from sugars and fat, while the output can be configured in many ways to
either extract direct mechanical work or convert the work to easily storable electrical
energy. It is seen that human power generation has multiple applications in modern
society. It can be useful when users are isolated as possible with natural disaster,
military deployment or being in a remote area. It also provides for an intuitive, easy to
implement and relatively low cost design, which is particularly useful in rural areas of
developing nations where skill in operating equipment and investment capital is limited.
The thought of using human energy as an alternative and renewable energy source is
gaining popularity to the level that businesses have formed around converting exercise
equipment such as stationary bikes and ellipticals to electricity generators.

2. The Potential of Human Power

When the energy intake of humans is considered, a large potential seems apparent.
Considering the standard 2000kcal of daily consumption (97W of power in, on
average), humans take in about 8.368MJ or 2324Wh of energy every single day. This
is approximately the same amount of energy stored in the typical car battery (2400Wh).
 3. Objective-
To design and develop a manual treadmill for electricity
or power generation.

4. Design of the Proposed Model

A device utilized by humans for walking, jogging, and running named as a treadmill
system. Two types of treadmills available which are: Motorized treadmill machine and
Manual treadmill machine. For the motorized Treadmill, it has a rotating belt driven by an
electric motor, the speed of walking belt treadmills controlled. In this case, the energy
consumed from an external source that is the electric energy converted into kinetic energy.
Whereas in manual treadmill speed of the belt is governed by the running speed of the
human. It does not have electrical connections, as the speed rate does not control by the
motor. The manual treadmill machine used with the proposed model in which the speed
rate of belt treadmills increased and doubled with the handling of gears. Here, a manual
treadmill system has been used and re-designed with the generator.

Source- A. https://5.imimg.com/data5/BK/UI/MY-40337003/manual-treadmill-500x500.jpg
B. https://images.app.goo.gl/g8ksBohga9nAvfjq8
4.1 Main Components of Treadmill with Electricity Generator

Source:https://www.researchgate.net/publication/289531806_DESIGN_OF_MANUAL_TRE
ADMILL_WITH_ELECTRICITY_GENERATOR_FOR_ENERGY_SAVING

The main components of the treadmill are as below:

1. Base frame 9. Upright Support

2. Left upright. 10. U-Shaped Handrail
3. Right upright 11. V-Grooved Flywheel
4. Flywheel 12. Electric Motor.
5. Roller
6. Working Belt
7. Side Moulding
8. Adjustable Bracket
4.2 Working Principle:

When someone walks runs on the walking belt flywheels runs and this flywheel rotation is used
to generate the electricity. For mounting the Electricity Generator, a support is welded on left
upright as shown in Fig. 2. An Electricity Generator is mounted on this support and a v-pulley
is fixed on the generator.

Side View of Manual Treadmill

Source:
https://www.researchgate.net/publication/289531806_DESIGN_OF_MANUAL_TREADMI
LL_WITH_ELECTRICITY_GENERATOR_FOR_ENERGY_SAVING
A walking belt is wrapped around roller 1 and roller 2. Roller 1 is mounted on the left and
right upright and roller 2 is mounted on lower end of the base frame. A V-grooved flywheel is
mounted on the left side of the roller 1 and another flywheel is mounted on the right and of the
roller 1 as shown in Fig 3.

Source:
https://www.researchgate.net/publication/289531806_DESIGN_OF_MANUAL_TREADMI
LL_WITH_ELECTRICITY_GENERATOR_FOR_ENERGY_SAVING
The V-Grooved Flywheel is connected with the V-Pulley mounted on Generator shaft through
a V-belt. When someone walks / runs on the walking belt rollers 1 and 2 rotate. As the V-
grooved flywheel is mounted on roller 1 and there is no relative motion between the flywheel
and roller 1. Thus V-grooved flywheel rotates with roller 1. The diameter of V grooved
flywheel is kept 5 times more than the diameter of the v-pulley mounted on the shaft of the
generator. If flywheel rotates at 200 r.p.m. the generator shaft will rotate at 1000 r.p.m. and
electricity will be generated which may be used to charge the battery or it may be used to run
the MP3 player, low voltage CFL etc.

4.3 Trends in use of Treadmills

One of the most popular ways to burn fat is to do aerobic or cardiac exercise such as walking,
running, cycling, swimming, etc. treadmills are known to be one of the most power hungry of
all exercise equipment. A study found measurements of power consumption from a variety of
automated treadmills to be about 480W at the modest speed setting of 5mph. At higher speed
settings, the high-power motors were found to consume even more energy, up to 1083W at
9mph. Treadmills were found to be the 3rd highest expenditure of energy overall.

The manual treadmill with Electricity Generator generates about 14- W max power per person
while Pedal operated stationary bicycle-based generator generates maximum power 100-244
watt. The treadmill generator can generate energy and this energy may be stored in the batteries
and later it may be useful for different applications. This energy generation system is
sustainable and free from adverse efforts. The treadmill with Electricity Generator reduces the
energy consumption resulting money saving. This system may be used in gym environment
and more energy may be produced which can be stored in batteries for operating different
appliances.
5. Applications of Generated Energy

Most modern human power generation efforts have instead been focused in converting and
storing the energy in electrical form. With a sustainable average output of 60-100W, the
device can continuously power personal electronics such as MP3 players, cell-phones,
tablets and laptop computers. Further, the energy can be directed to the local grid where it
could contribute to powering low wattage, high efficiency lights or basic fan ventilation.
The energy can also be used to enhance the workout experience by providing incentive to
continue running. An example of this would be a music speaker system powered by the
treadmill that could get louder with increasing speed but turn off when the running stops.
Furthermore, the treadmill generator can extract energy and store it in batteries, later to be
useful for powering a wider variety of applications.

The treadmill generator can also prove to be useful in isolated situations such as in rural
areas or developing countries. The major advantages the system would have over other
generation methods (solar, wind, fossil fuel) are as echoed in for a pedal powered generator;
the implementation would be relatively simple, the system over its lifetime would be cost
effective and minimal training would be required in its operation.

Further, the simplistic design attributes limited maintenance requirements and components
that would be inexpensive to replace if broken. Not to mention, there would be no material
fuel needed other than food and water, which is expected to be provided as a basic need for
life. Additionally, the general technical aptitude of people in developing countries can be
limited, especially in rural areas, but this generator would require minimal skill in operation
as the main process is through walking or running. These characteristics enable the
treadmill generator to be a viable option for producing power in isolated situations, helping
deliver electricity and its benefits to places hard to reach from the grid.

In addition, the method promotes good health, as treadmills are a known way of
cardiovascular exercise, particularly important in the current situation of overweight and
obesity levels. In fact, exercise on manual treadmills can burn more energy when compared
to automatic machines, accelerating the rate of calorie burning for affected persons.
 Various Parts Design
(Before Assembly)

Upright D.C. Motor

Pulley
Front View Side View

Top View Isometric View

SPECIFICATIONS OF COMPONENTS:
S No. Components Dimensions Material Costing

1. Base Frame Frame Length: 66 cm Cast Iron 300

Frame Width: 38 cm
Thickness: (2.5*5) cm

2. Roller Length: 30 cm Chrome Steel 450

Diameter: 30 mm

3. Belt Length: 110 cm Fabric 200

Width: 28 cm
Thickness: 1.5 mm

4. Freewheel Diameter: 7.5 cm Iron 100

Number of teeth: 18

5. DC Motor Voltage Rating: 12V ---- 100

Current Rating: 500mA

6. Flywheel Diameter: 23 cm Cast Iron 200

Width: 1.5 cm
Weight: 3.5 kg

7. Pulley Diameter: 13 cm Plastic 50

8. Bearing Inner Diameter: 12 mm Steel 500

Outer Diameter: 28 mm
Bore: 8 mm
Basic dynamic load rating, C = 5.4
kN.
Basic static load rating, C0 =2.36
kN.
Fatigue load limit, Pu = 0.1 KN
Reference speed = 60 000 r/min
Limiting speed = 38 000 r/min
Calculation factor, Kr = 0.025
 Final Output

Current Rating Voltage Rating

While Walking-(4 km/hr.) (approx.)

Voltage Output- 2.74V
Current Output- 138.9 mA
Power- 0.38 W.
 Current Rating Voltage Rating

While Running-(8 km/hr. (approx.)

Voltage Output- 10.27V
Current Output- 198.8 mA.
Power- 2.04 W
Analysis On Different Components:
1. Bearings:
Inner Diameter: 12 mm
Outer Diameter: 28 mm
Bore: 8 mm
Basic dynamic load rating, C = 5.4 kN, (Weight = 551 kg)
Basic static load rating, C0 =2.36 kN, (Weight = 240 kg)
Fatigue load limit, Pu = 0.1 kN
Reference speed = 60 000 r/min
Limiting speed = 38 000 r/min
Calculation factor, kr = 0.025 [Reference: Design Data book]

Calculations:
Equivalent dynamic load is given by, P = X*V*Fr + Y*Fa

Where, P = equivalent dynamic load (N),

Fr = Radial load (N) Fa = Axial or thrust load (N),
V = Race rotation factor
Fr = (200*9.8)/4
Fr = 490.5 N, Fa = 0 N
Hence, the bearing is subjected to Pure bearing load.

The value of V is 1.2 when the outer race rotates w.r.t. Load, while the inner race
remains stationary.
Hence, New value of equivalent dynamic load is given by,
P = V * Fr = 1.2*490.5 = 588.6 N
Bearing life (L10):
We take L10h = 16000, From V.B.B table 15.24
L10 = (60*n* L10h)/106
Where, n = Speed of rotation (rpm)
L10h =Rated bearing life (hours), L10 = Bearing life (mill.revln)
L10 = (60*1500*16000)/ 106 = 1440 mill. revln.
 Then, we find Dynamic load capacity (C):
C = P * (L10h) 1/3 = 588.6 (1440)1/3
C = 5.4 kN.

2. Roller:
Diameter = 30mm, Length = 30 cm.

Calculations:
Load analysis of the selected material: -
Maximum applied load = 150kg = 1471.5 N
Design of roller: - Maximum allowable load = 150 kg = 1471.5 N
Length of roller = 300 mm.
Uniform distributed load= 4.91 N/mm (Consider simply supported load.)
Material: - Chrome Steel Tubes, cold drawn and tempered.
Yield strength (Syt) - 300 N/mm2
Ultimate tensile strength (Sut) - 400 N/mm2
Ƭp = 0.3*Syt = 0.3*300 = 90N/mm2
Where, Ƭp = Permissible shear stress, Syt = Yield tensile strength.
Ƭp = 0.18*Sut = 0.18*400 = 72 N/mm2
Where, Ƭp = Permissible shear stress, Sut = Ultimate tensile strength.
Selecting whichever is smaller value – Ƭp = 72 N/mm2

3. BELT SELECTION:
Normally standard belt sizes are available in market of sizes ranging from
Ranges: Length: - 40inch to 60inch
Width: - 11inch to 22inch
In our project we have used a belt of
Length = 44 inch. Width=12 inch.
 Conclusions:

• Electrical energy can be saved by using this manual treadmill with Electricity
Generator.
• This manual treadmill with Electricity Generator is less expensive.
• A wide range of health problems can be managed using this manual treadmill.
• This treadmill with Electricity Generator is useful for such areas where electricity is
not available.
 References:

1. Harsh Mankodi, “Analysis of a Treadmill Based Human Power Electricity Generator”,

Submitted under the supervision of Prof. Rusen Yang to the University Honours Program

at the University of Minnesota-Twin Cities in partial fulfilment of the requirements for the

degree of Bachelor of Mechanical Engineering, cum laude. June 30, 2012.

2. Manish Debnath,” Generation of electricity by running on a leg-powered treadmill”,

International Journal of Latest Research in Engineering and Technology (IJLRET), ISSN:

2454-5031(Online), www.ijlret.com, Volume 1 Issue 7, December 2015, PP 04-07.

3. Shamshad Ali, Syed Tariq Murtaza, “Design of manual treadmill with electricity generator

for energy saving”, International Journal of Research in Engineering and Applied Sciences

, (ISSN 2249-3905)