TITLE PAGE

CONVERSION OF 2.9KVA PETROL GENERATOR TO 3.6KVA

FUELESS/NOISELESS GENERATOR

BY

AHMAD AMINA JODA

SBET/NDBMET/030212

A PROJECT REPORT SUBMITTED TO THE FEDERAL SCHOOL OF

BIOMEDICAL ENGINEERING TECHNOLOGY, AHMADU BELLO UNIVERSITY

TEACHING HOSPITAL ZARIA, IN PARTIAL FULFILLMENT OF THE

REQUIREMENT FOR THE AWARD OF NATIONAL DIPLOMA IN BIOMEDICAL

ENGINEERING TECHNOLOGY.

NOVEMBER, 2023

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 DECLARATION

This is to certify that this project work on the conversion of 3.6kva furless/noiseless generator

was conduct and written by me under the supervision of Engr. A.T UTEV of school of

biomedical engineering technology Ahmadu Bello University Teaching Hospital, Zaria.

_______________________ _______________________

AHMAD AMINA JODA Date

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 CERTIFICATION

This is to certify that this project work on conversion of 2.9KVA to 3.6KVA

fuel-less/noiseless generator has been read and approved and also met the requirement for the

award of National Diploma in Biomedical Engineering Technology, Ahmadu Bello

University Teaching Hospital (ABUTH), Zaria.

_______________________ _______________________

Engr. A.T UTEV Date

Project Supervisor

_______________________ _______________________

Engr. Johnson A. Odiba Date

Project Coordinator

_______________________ _______________________

Engr. M.O Bamidele Date

School Coordinator

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 DEDICATION

To Almighty Allah is the glory for sparing me all the mercies and love to the completion of

my national diploma program.

This write up is also dedicated to my parents (Alh. Ahmad Ali Joda and Asma'u

Muhammad), my sisters and brothers.

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 ACKNOWLEDGMENT

Sincere and honest appreciation be to god Almighty foe giving me knowledge and wisdom to

put this project work together my appreciation goes to my father, mother, brothers and sisters

for their kind of support and prayers

My profound gratitude and appreciation goes to my able supervisor in person of Engr. A.T

UTEV who despite his fight and busy scheduled gave time and instruction that lead to the

success of this work.

Lastly, I want to thanks and appreciate the efforts of my lectures, instruction Engr. A.T Utev,

Engr. Awe M. Gbenga, Engr. Nuraddeen Aliyu, Engr. Johnson A. Odeba, Engr. Abdulrazak

Aliyu for their positive contribution in one way or the other for the successful

accomplishment of this project.

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 ABSTRACT

This is on conversion of 3.6KVA fuel-less power generator it is constructed to meet up with

power demand in the offices, school and in homes in the absence of power supply from the

national supply Authority, NEPA. In other word the items and devices serves as a substitute

for NFPA (PHCN) which almost monopolize the power supply to the people and also are

conventional generator. There device bare overcome the need for conventional generator

becomes it uses no fuel generate power supply and it is less noise. It make less noise during

operation and no hazardous carbonmonoxy is generated in the surrounding. This is a feature

that make it safe to use anywhere when compare to generator the programmed of the work

done describe in this project work represented and exploration of the working principal of a

generator without the use of fuel or any type of liquid, hence fuel less generator which are

invented by Nikola tesla after patenting a successful method for producing alternative

current. He claimed the invention of electric generator that would that will consume fuel.

However, the system design comprises of this method of construction, principle of operation

experiment, test and results.

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 TABLE OF CONTENT
Title Page -- -- -- -- -- -- -- -- -- -- i
Declaration -- -- -- -- -- -- -- -- -- -- ii
Certification -- -- -- -- -- -- -- -- -- -- iii
Dedication -- -- -- -- -- -- -- -- -- -- iv
Acknowledgment -- -- -- -- -- -- -- -- -- v
Abstract -- -- -- -- -- -- -- -- -- -- vi
Table of Contents -- -- -- -- -- -- -- -- -- vii
CHAPTER ONE: GENERAL INTRODUCTION
1.0 Introduction -- -- -- -- -- -- -- -- -- 1
1.1 Background to the Study -- -- -- -- -- -- -- -- 2
1.2 Aims and Objectives of the Study -- -- -- -- -- -- 3
1.3 Scope of the Study -- -- -- -- -- -- -- -- 3
1.4 Significance of the Study -- -- -- -- -- -- -- 3
1.5 Problem of the Project -- -- -- -- -- -- -- -- 4
1.6 Limitation of the Project -- -- -- -- -- -- -- -- 4
1.7 Benefit of the Project -- -- -- -- -- -- -- -- 4
1.8 Project Outline -- -- -- -- -- -- -- -- -- 5
CHAPTER TWO: LITERATURE REVIEW
2.0 Introduction -- -- -- -- -- -- -- -- -- 6
2.1 Historical Background -- -- -- -- -- -- -- -- 6
2.2 Review of Past Works on the Fuel Less Generator -- -- -- -- 6
2.3 Uses of Fuel Less Generator -- -- -- -- -- -- -- 7
2.4 Advantages of Fuel Less Generator -- -- -- -- -- -- 8
2.5 Disadvantages of Fuel Less Generator -- -- -- -- -- -- 8
2.6 Types of Fuel Less Generator -- -- -- -- -- -- -- 8
CHAPTER THREE: MATERIALS AND METHODS
3.0 Introduction -- -- -- -- -- -- -- -- -- 10
3.1 Materials -- -- -- -- -- -- -- -- -- 10
3.2 Fuel-Less Power Generating Set Components Units -- -- -- -- 11
3.2.1 The Power Supply Unit -- -- -- -- -- -- -- 11
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3.2.2 Conversion Unit -- -- -- -- -- -- -- -- 11
3.2.3 Control Unit -- -- -- -- -- -- -- -- 11
3.2.4 Output Unit -- -- -- -- -- -- -- -- 12
3.3 Constructional Features -- -- -- -- -- -- -- -- 12
3.3.1 The Alternator -- -- -- -- -- -- -- -- 12
3.3.2 The DC Motor -- -- -- -- -- -- -- -- 12
3.3.3 12V Battery -- -- -- -- -- -- -- -- 13
3.3.4 Battery Charger -- -- -- -- -- -- -- -- 14
3.3.5 Coupler -- -- -- -- -- -- -- -- 14
3.3.6 The Frame -- -- -- -- -- -- -- -- 15
3.4 Material Selection -- -- -- -- -- -- -- -- 15
3.5 Methods -- -- -- -- -- -- -- -- 16
3.5.1 Introduction -- -- -- -- -- -- -- -- 16
3.5.2 Equipment and Tools that were Required -- -- -- -- -- 16
3.6 Manufacturing Techniques Utilized -- -- -- -- -- -- 17
3.7 The Fabrication and Assembling Process -- -- -- -- -- 18
CHAPTER FOUR: PERFORMANCE AND EVALUATION
4.0 Introduction -- -- -- -- -- -- -- -- -- 19
4.1 Machine Evaluation -- -- -- -- -- -- -- -- 19
4.1.1 Input Parameters -- -- -- -- -- -- -- -- 19
4.1.2 Output Parameters -- -- -- -- -- -- -- -- 20
4.1.3 Relationship between Generator Speed and Power Produced -- -- -- 20
4.2 Bills of Engineering Material and Evaluation -- -- -- -- -- 20
CHAPTER FIVE: CONCLUSION AND RECOMMENDATIONS
5.0 Future Prospects of Fuelless Generator -- -- -- -- -- -- 21
5.1 Conclusion -- -- -- -- -- -- -- -- -- 21
5.2 Recommendations -- -- -- -- -- -- -- -- 22
References

viii
 CHAPTER ONE

GENERAL INTRODUCTION

1.0 INTRODUCTION

Power generation and distribution has been an indispensable factor in the progress of an

economy, ranging from manufacturing, banking, media healthcare, aviation etc.

Environmental pollution which leads to degradation or depletion of ozone layer is one of the

major problem caused by the use of generator with fossil fuels. Increase in the cost of fossil

fuel which has been one of the major prime movers in the internal combustion engine (ICE)

has been noticed. This can be accounted for based on the rapid decrease in the level of oil

well. Hence, there is need for development of a power generating set that will not make use

fuel to produce voltage. This study deals with the design and construction of a fuel less power

generating set to serve as an alternative source of energy.

This device convert DC power (also known as direct current) to standard AC power

(alternating current) fuel less generator are used to operate electrical equipment from the

power produced by a car or boat battery or renewable energy source like solar panels or wind

turbines. DC power is what batteries store, while AC power is what most electrical appliances

need to run so generator is necessary to convert the power into a usable form. The wave form

fuel less generators are used to operate sensitive electronic devices that require high quality

wave form with little harmonic distortion. In addition, they have high surge capacity which

means they are able to exceed their rated wattage for a limited time.

This enables power motors to start easily which can draw up to seven times their rated

wattage during start up. Virtually any electronic device will operate with the output from a

pure sine fuel less generator.

Sine wave fuel less generator has the following characteristics;

- High efficiency

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 - Low standby losses

- High surge capacity

- Low harmonic distortion

All fuel less generators are pure sine (true sine), hence the grid by nature is a pure sine wave

electricity source the importance of pure sine wave generator may be apparent especially for

off grid applications such as RV boat or cabins, they are used for connecting a battery source

or a solar PV system to an AC load such as home appliance, a laptop charger, a TV.

1.1 BACKGROUND TO THE STUDY

The global consumption of energy is growing and there is need for new renewable energy

sources. Among the following energy sources that could be free from carbon dioxide are

wind, wave and tidal of photovoltaic and osmotic power. But fuel less engine is still most

dependable low maintenance. Cost energy new renewable low maintenance cost energy new

renewable solutions the use of low cost conventional energy such as fossil fuels will continue

to be major source of energy until next decades, despite their adverse effect on environment,

the pressure on the environment by human activities compiled with carbon dioxide emissions

calls for thorough research on the alternatives.

Now a new principle can be applied to electricity generation leading to electricity cycle,

bringing electricity revolution in Nigeria. Ordinarily conventional electricity generators make

use of fuel or solar/wind or nuclear energy. In the case of fuel (in this analysis fuel can be

petrol, diesel, steam, charcoal, kerosene) an internal combustion engine is involved this

engine uses the chemical energy in the fuel converts it into mechanical energy that will be

used to drive the alternator thereby generating electricity based on the principle of

electromagnetic induction. Today Nigeria faces a destabilizing dependency on irreplaceable

fossil fuels which are also rapidly dwindling. As shortages of oil and natural gas occur with

more frequency, the “New Energy Crisis” is now heralded in the news media.

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However an alternative source of energy that can replace fossil fuels has not been reliable

demonstrated. A fuel need exists for portable source of power that can compete with fossil

fuel and its energy density. A further need exists on land, in air and in space for a fuel less

source of power which by definition does not require refueling the future freedom and quite

possibly the future survival of mankind depend on the utilization of such a source of energy if

it exists in order to find other ways of producing energy.

1.2 AIMS AND OBJECTIVES OF THE STUDY

The aim of the work is to create a generator, capable of producing 3.6 KVA of electricity

energy/power which can generate electricity without using any fuel.

The objectives are as follows;

i. To build fuel less generator prototype

ii. To generate electricity without using fossil fuel

1.3 SCOPE OF THE STUDY

This study is focused on the conversion of mechanical energy into electrical energy without

combustible fuels.

It deals with the assessment of the actual advantages in term of efficiency, fuel free

performance and cost maintenance free.

It involves proper material selection, drafting of working drawings and basic operations of

pure fuel less generator.

1.4 SIGNIFICANCE OF THE STUDY

This study on how to convert a fuel generator to fuel less generator is becoming more

necessary because as long as the price of fuel is high and the power holdings company of

Nigeria (P.H.C.N) keep disappointing it is recommended that one should fall back on this of

personal electricity generator (P.E.G).

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The significance of the study are as follows;

i. Show the detailed process employed in the construction of the fuel less generator.

ii. It saves the money spent on gas and petrol so it is economical.

iii. Acquire knowledge of the materials used in the design and construction of the

project work.

iv. Low maintenance.

v. It can be used indoor.

1.5 PROBLEM OF THE PROJECT

Initially you need to shell out a lot of money for buying a fuel less generator, it will work

effectively and produce direct current only when the battery is fully charged. Maintenance

and replacement may require more effort in the event of a problem a technician will need to

access the roof to make repairs depending on your maintenance plan and warranty this may

cost your money.

1.6 LIMITATION OF THE PROJECT

- This device can be damaged when the load exceeds or equal to the rated power of the

device.

- The inverter frequency is rated at 50 Hz.

- Iron casing and good heat sink is being used for heat absorption.

1.7 BENEFIT OF THE PROJECT

The fuel less generator is a self-sustained generator which produces electric energy for

consumption that is to say H powers itself and simultaneously supplies power in a way it can

be also looked at as a form of renewable energy system. The benefits this machine gives

include;

1. The fuel less generator can be operated for hours at a time without the use of fuel.

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 2. It is environmentally friendly as it produces no noise (noiseless operation), smokeless.

In fact it is possibility that an existing fuel generator can be converted into a fuel less

generator by replacing the engine with the electromechanical device.

DIFFERENCE BETWEEN CONVENTIONAL GENERATOR AND FUEL LESS

GENERATOR

Conventional generator have been around for quite a while and the basic concept behind them

has remained essentially unchanged, they consist of an energy source, usually a fossil fuel

such as diesel, propane or gasoline, which powers a motor attached to an alternator that

produces electricity. The motor must run at a constant speed, fuel less generators are a

relatively recent development made possible by advanced electronic circuitry. It inverter

draws power from a fixed DC source (typically a comparatively fixed source like a car

battery or a solar panel) and uses electronic circuitry to “invert” the DC power into the AC

power, the converted AC can be at any required voltage and frequency with the use of

appropriate equipment but for consumers level applications in Nigeria the most common

combination is probably taking the DC power from required for most everyday uses,

conventional generators always bigger and heavier than inverter.

1.8 PROJECT OUTLINE

This project consist of five chapter enumerated below;

1. Chapter one consist of brief information about 3.6KVA generator its aim and
objectives, project motivation, purpose of the project, scope and limitations and the
benefits of the study.
2. Chapter two shows the literature review and other information about 3.6KVA fuel
less generator.
3. Chapter three explain the commencement of the research work, the materials used to
fabricate the project design and also the method used to analyse it.
4. Chapter four shows the testing and result analysis.
5. Chapter five comprises the conclusion and recommendation.

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 CHAPTER TWO

LITERATURE REVIEW

2.0 INTRODUCTION

This chapter aims at reviewing relevant literature on the topic under this chapter, terms such

as history of generators will be first conceptualized follow by early development of fuel

less/noiseless generator and recent developments of fuel less/noiseless generator. Similarly

this chapter will also focus on empirical review studies on the benefits of electricity, the

electric power supply nature experience in Nigeria, effect and environment pollution caused

by the use of fuel generators.

2.1 HISTORICAL BACKGROUND

The fuel less generator, a machine and device based on the principle of advanced physics

which was put in place by a Siberian Boin physicist and electrical engineer and as well as

mechanical engineer by profession Dr. Nikola Tesla 1880.

Dr. Nikola Tesla applied the theory of the tremendous tungsten like explosion known as

Tunguska explosion which shuuk central sibena in 1908 in his engineering work utilizes and

conductive disks relating in magnetic field to produce an electric current. His engineering

accomplishment particularly the AC generator, transformer and motor translated easily from

the older to the newer scientific world views.

Ten years after invention of electric motor in 1880, in 1890 a new type of electrical generator

which was to extract energy directly from the ambient working medium was coupled by Dr.

Tesla which obeys the second law of thermodynamics.

2.2 REVIEW OF PAST WORKS ON THE FUEL LESS GENERATOR

The exact nature of electricity is not known but investigator indicates that it consist of small

negative charge called electron when this electron are standing still, static electricity is said to

be developed and when they are forced to travelled a movement of electron they are called

6
“Dynamic Electricity” power generation and distribution has been an indispensable factor in

the progress of an economy, ranging from manufacturing, banking media, healthcare,

aviation etc. (Ulaby 1999). It has however been proved that power skyrocket the productivity

of a country since power has been defined by knight (2004) as the rate of doing work, this

simply means that the productivity of power different source. Thus Hassan (1998) state the

majority of the Description of Components;

Alternator: is an electrical component that convert mechanical energy into electrical energy

in the form of alternating current.

Electric Motor: electric motor is the electro mechanical machine which converts the energy

into mechanical energy in other words, the devices which produce rational force.

DC Motor: a DC motor is any of a class of a rotary electric motors that convert direct current

(DC) i.e. electrical energy. It turns thereafter the alternator with the power gotten from the

12v battery it involves 300per minutes.

Battery: this is a DC rechargeable battery pack it is connected to DC motor there by

powering it.

Battery Charger: a battery charger or a recharge is a device that store energy in a battery by

running an electric current.

Coupler: coupler is component used in connection a driving shaft and driver part in

connection DC motor and alternator.

2.3 USES OF FUEL LESS GENERATOR

Fuel less generator are used in all day to day activities in our home, school, office and

industries to power equipment, television, air condition. This generator is to generate

3.6KVA and above of power within which could be used in the house it could use to power

the following gadgets;

- A 6hp Air Condition

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 - A Microwave

- The audio sound system or its equivalent (MAC, NELSON)

- An Electric Iron

- A Thermocool Freezer

- A Television set

2.4 ADVANTAGES OF FUEL LESS GENERATOR

- They are noiseless

- They cause no environment pollution

- They are easy to build

2.5 DISADVANTAGES OF FUELLESS GENERATOR

- It efficiency can be affected by overtime

- It can get damaged easily especially if soaks in water

- It doesn’t run for a long of time without breaks

2.6 TYPES OF FUELLESS GENERATOR

According to Morita AI (2002), the fuel-less generator can be categorized into.

2.6.1 OF F-GRID FUEL-LESS GENERATOR: Is used in isolated system where the

inverter draws its DC energy, from batteries charged by solar arrays and/or other sources,

such as wind tribune, hydro turbines etc. Normally these do not interfere in any: way with the

utility grid, and as such are not required to have anti-islanding protection.

2.6.2 GRID-FIELD FUEL-LESS GENERATOR: - These systems match their phase ‘with

utility-supplied sine wave. Grid-tie fuel-less generator is designed to shutdown automatically

upon loss of utility supply (referred to as anti-islanding protection). They do not provide

backup power during utility outages. In untario, any solar arrays that feed the utility grid

(under the FIT/ micro-FIT programs for example) are required to have anti-islanding

protection.

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2.6.3 BATTERY BACKUP: - These are special fuel-less generator which are designed to

draw energy from a battery, manage the battery charge via an on board, and export excess

energy to the utility: outage, and are required to have anti-islanding protection. 4 However,

perry, (1999) also classified the fuel-less generator under two types, the wet and dry type

fuel-less generator.

The wet-type fuel-less generator: as the name implies, is a type of fuel-less generator that

make use of any component that contains liquid (e.g battery) to enhance of an electric DC

motor power. It mainly consists of an electric DC motor an electric generator, couplings and

battery.

The dry-type fuel-less generator: it is an environmentally friendly type of generator that does

not make use of battery. These systems basically consist of an AC electric motor, flywheel,

pulleys, belt drives, shaft and electric generator.

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 CHAPTER THREE

MATERIALS AND METHODS

3.0 INTRODUCTION

This Fuelless generator is constructed in the School of Biomedical Engineering and

Technology Ahmadu Bello University Teaching Hospital, Zaria in the Biomedical/Electrical

Laboratory. All material was locally sourced, some from Alaba International junction shop,

Lagos State and others from Sabon Gari market, Zaria, Kaduna State.

Design Illustration of the Fuel-less Generator

Block diagram

3.1 MATERIALS
1. Dc Motor
2. Alternator
3. 12v Battery
4. Coupler

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 5. Charger
6. Cables
3.2 FUEL-LESS POWER GENERATING SET COMPONENTS UNITS
The fuel-less power generating set consists of five major units, which includes the following;
- The power supply Unit.
- Conversion Unit.
- Control Unit.
- Output Unit.
- Charging Unit
3.2.1 The Power Supply Unit
12 volts battery was used as source of power supply unit to the D.C motor in order to induce
electromotive force (e.m.f). Lead acid battery is highly recommended for DC generating
system. This serves as storage device for the direct current which is to be induced
3.2.2 Conversion Unit
This unit is the unit that distinguished the DC generator from the popular fuelled generating
set. The unit makes use of DC motor, which will be responsible for all voltage, current and
power conversion.
3.2.3 Control Unit
This unit performs the following work; converts direct current (DC) to alternating current
(AC), removal of ripples, and rectification. The size of the alternator been used, will
determine the capacity of the generating set.
Mathematically; P = IV cos Ф (i)
Where
P = Power output (watts) =?
V = Voltage (Volts) = 220
I = Current (ampere) = 16.5A
Cos Ф = 0.8
Therefore, the capacity of the generating set,
P = 16.5 x 220 x 0.8 = 2900W
The alternator which is a small domestic generator has three output lead cables which
supplies the load and charger.
Crank Shaft

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The crankshaft acts as a link between the DC motor and the alternator which transfer the
mechanical energy from the DC motor into the alternator to produce electric current.
3.2.4 Output Unit
The use of the control circuit unit will make it possible to provide output voltage within the
range of 100V - 240V which is the standard voltage requirement for all appliances. The red
wire on the alternator was used to supply the household and offices as the mains.
3.3 CONSTRUCTIONAL FEATURES
The constructions feature is displayed below:
3.3.1 The Alternator
The choice and selection of an alternator depends on the capacity required by the intended
user. According to Kingsley Nwaogbo (2010), an alternator required for used in a fuel-less
generator should be 20% higher than the intended load capacity. The generator was also
selected based on availability. Therefore, the generator for the project was obtained from a
2.9Kw petrol generating set that was abandoned due to bad combustion unit.

Alternator

3.3.2 The DC Motor

The main criterion for the selection of the DC motor is the efficiency of energy transfer from

the power supply unit to the alternator. It is known that AC motors are designed to give

maximum efficiency at, or near the rated load (Theraja, 2005). Another consideration was the

speed of the AC motor. It is well known that the frequency of the generated voltage in an

alternator is given by:

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 p n
𝑓= x …………………………………...…… (3.1)
2 60

Where P is the number of poles of the generator, and n is the rotor speed in rpm. For the same

reason, a constant speed motor was desired so that from no load to full load, the same

frequency of generated voltage would be obtained. Thus, for a 50Hz generated voltage using

a two pole generator, the specification of the motor selected for this study is a 2HP a DC

motor with a maximum operational speed of 2600 rpm.

A DC Motor.

3.3.3 12V Battery

An electric battery is a source of electric power consisting of one or more electrochemical

cells with external connection for powering electrical devices. When a battery is supplying

power, its positive terminal is the cathode and its negative terminal is the anode. The terminal

marked negative is the source of electrons that will flow through an external electric circuit to

the positive terminal. When a battery is connected to an external electric load, a redox

reaction converts high-energy reactants to lower-energy products, and the free-energy

difference is delivered to the external circuit as electrical energy.

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 12v battery

3.3.4 Battery Charger

A battery charger or a recharger is a device ,that stores energy in a battery by running an

electric current through it.it is used to charge the battery back as the system generate

electricity.

Battery charger

3.3.5 Coupler

A coupler is a mechanical device that serves to connect the end of adjacent object. Is a link or

rod transmitting power between two rotating part and a reciprocating part. This couple is in

pair where one is coupled to the end of the shaft of the dc motor and the other to the end of

the alternator.

Coupler

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3.3.6 The Frame

The generator frame and housing provide the structural support and protection for the internal

workings of the generator. The main frame or skid is the housing of the generator that hold on

it all parts and component. The frame also, can be designed to allow the generator to sit on

the ground or a concrete pad or it can be mounted to a trailer for easy transportation of the

system.

The Frame

3.4 Material Selection

During the project design, adequate material selection is ensured to enhance efficient

functionality of the project design as shown in Table 3.1; the following factors are the key

areas considered to enhance the functionality;

 Reliability.

 Complexity.

 Ductility.

 Tensile strength.

 Resistance to corrosion.

 Available of materials.

 Machinability.

 Weight Reduction.

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 Table Breakdown of Components and Materials used

Component 1.1 Material Justification

Main frame(support) Structural steel Cheaper and has high strength to weight ratio

Shaft Mild steel High resistance to breakage

Coupler Cast iron High resistance to breakage

Bolts and nut Alloy steel Hardness and high strength

3.5 METHODS

3.5.1 INTRODUCTION

Fuel-less generator is a device made up of different components joined, fixed or coupled

together to act as a single unit for the purpose of generating electric current/electricity.

In this section, the equipment/measuring instruments used will be taken into consideration,

the various manufacturing process that were adopted and the sequences of operation that

were taken in order to successfully fabricate the project are also considered.

3.5.2 EQUIPMENT AND TOOLS THAT WERE REQUIRED

The equipment/tools that were required for the fabrication are as follows:

 Measuring tape: The measuring tape is used for measuring length that is large, it is

used to determine, measured the actual length of the flat bars and other parts in the design.

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 Measuring Tape

Other tools used show

 19 flat spanner

 19 heads spanner

 Screw driver (flat & star)

 Two nose pliers

 Ammeter (for testing of the output current).

Other tools used

3.6 MANUFACTURING TECHNIQUES UTILIZED

3.6.1 Marking out

Marking out was done by transferring shapes and lines onto the material (steel metal sheet),

to provide guide for cutting, bending, shaping and various other processes. Accurate marking

out and measuring are important in ensuring the materials will fit together properly. The

marking out tools used were;

 T square

 Measuring table

 Scriber

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 The cutting was accomplished by using single-point or multiple tools.

3.7 THE FABRICATION AND ASSEMBLING PROCESS

In general, the required size of the frame were fabricated and assembled with bolts and nuts.

Battery would be seated together to produce the frame structure. The following procedures

were adopted to build the machine;

Step 1: Involves fabricating a crankshaft and boring a reasonable hole that will conveniently

fit in to the DC motor, and the alternator with thread hole for bolting to the crankshaft.

Step 2: Involves fitting the fabricated crankshaft in to the DC motor.

Step 3: Involves inserting the coupler in between the DC motor and alternator, and tightening

it firmly to connect the motor and the alternator together.

Step 4: Involves connecting the terminals of the DC motor to equivalent terminals of the

battery.

Step 5: Involves connecting the electrical cables to the AC mains as output.

Step 6: involve connecting or wiring of charger (rectification) from the alternator to the

battery.

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 CHAPTER FOUR

PERFORMANCE AND EVALUATION

4.0 INTRODUCTION

This section presents the result of the input and output data. The results were obtained base

on both the evaluation of the models presented in section three and the fabricated design. The

input data are tabulated for clarity.

4.1 Machine Evaluation

In order to ascertain the workability, reliability, and operating characteristics of the fuel less

generator, tests were carried out severally on both unloaded and loaded conditions. The

results of these tests were then use to validate the fuel-less generator with the already existing

ones.

The evaluation of the machine can be calculated using the formula stated by Akintunde et al

output power
(2004); Efficiency = 𝑥 100 ……………………………… (4.1)
inputpower

4.1.1 Input Parameters

The input parameters as shown in Table 4.1 represent the known values from which the

general design was based upon. It includes the DC motor and generator to produce the

required voltage which was obtained from the specification of the DC motor purchased.

Table 4.1.1: input parameters for the analysis

S/N PARAMETER VALUE UNIT

1. Generator power rating 3.6 KVA

2. Motor power rating 2 HP
3. Rotational speed of generator 3600 r/min
4. Rotational speed of motor 2600 r/min
5. Diameter of the DC motor shaft 22.55 mm
6. Diameter of the Alternator shaft 20 mm
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20
4.1.2 Output Parameters

The results obtained from the evaluation of the models in chapter three are:

 Current:- 16.5A

 Voltage:- 220V

4.1.3 Relationship between Generator Speed and Power Produced

From the analysis, it was observed that the power produced by the electric generator

increased as the rotational speed of the generator increased. Hence, to harness a great power

output from the generator, the speed of the generator is needed to be kept at its maximum

intensity. It was also observed that to keep the generator running at high speed, the coupler is

needed to rotate at a very high speed. Thus increasing its rotational speed and subsequently

increasing the speed of the generator which analogously increases electrical output and hence

the efficiency of the generator.

4.2 Bills of Engineering Material and Evaluation

S/N ITEM DESCRIPTION QUATITY AMOUNT

1 DC MOTOR (2HP) 1 85,000
2 CHARGER 1 14,000
3 COUPLER 1 26,000
4 TRANSPORT MONEY - 17,000
5 COIL RE-WINDING - 15,500
6 WORKMANSHIP - 1,500
7 ENGINE SIT 4 1,600
8 BANK CHARGES - 2,500
9 SUPER GULU 1 200
10 BAG OF WATER 1 200
11 RECHARGE CARD - 1,500
12 BATTERY TERMINAL 2 1,600
TOTAL 166,400

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 CHAPTER FIVE

CONCLUSION AND EVALUATION

5.0 FUTURE PROSPECTS OF FUELLESS GENERATOR

When D.C motors of higher capacity than 500hp are coupled to the alternator whose

capacities are lower than that of the D.C motors, then maximal output capacity of the

alternator could be obtained. Fuelless engines can be incorporated into automobiles in order

to have fuelless automobiles that would run without fuel

5.1 CONCLUSION

The need to switch from the use of synthetic fuels due to the effect of global warming caused

by the use of fossil fuels among other reasons has necessitated exploration of other means of

energy generation. Although several attempts have been made to come up with a means of

energy generation like this, these fuelless generators are easy to build and operate, and are

likely to be one of the most appropriate for developing countries as a source of decentralized

power supply to rural communities and industries. The fuelless engine usually runs very

smooth and quiet and the best part of the design is that it is free from air pollution, since there

is no emission of dangerous gas like Carbon monoxide (CO), carbon-dioxide (CO2), etc. The

speed are adjustable or can be built to run at one speed with engine which does not run on

any type of gasoline, oil or other combustible fuel. The free electrical energy produced by the

fuelless generators is replaced back into the motor and reused by the motor.

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5.2 RECOMMENDATIONS

Based on the design, construction and performance evaluation test conducted on this 3.6KVA

fuelless power generating set, the following recommendations were made for further study;

1. The source voltage that powered DC motor should be about 12v battery in order to

obtain a very good performance characteristic.

2. Engineers should be encouraged by specifically design of DC motor, alternator and

transformer for construction of fuelless generator as a source of renewable energy.

3. Fuelless power generating set should be embrace and made available for the use in

our country Nigeria.

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