A

Project Stage-II on
“TRAIN AXLE POWER GENERATION THROUGH
MAGNETIC COUPLINGS”

Presented By:-
GROUP- Guided by:-
1)
2)
3)

Department of Mechanical Engineering

1
 ABSTRACT
• This project aims at production of electricity by using the concept of the rotation of
secondary shaft due to the primary railway axle caused by the moving train by using
an electrical power generation system.

• This device could be placed along railway bogies or locomotive axles.

• An electrical power generation system comprises a variable capacitor and a power

source.

• The magnetic coupling here by used will transfer power from locomotive axle to the
generator shaft without contact that will implies no contact / friction load on railway
locomotive shaft.

• That will beneficial for power generation without altering or damaging ongoing
system.
 CONTENT
• Introduction
• Problem statement
• Objective
• Scope of the project
• Literature review
• System description
• Advantages
• Application
• Conclusion
• References
 INTRODUCTION
• Electricity has become a need of every single human, demand of electricity
increasing day by day.

• This new generation needs lots of electrical power for their different
operations.

• The human bio-energy being wasted if it can be made possible for

utilization it will be very useful energy sources.

• The human waste foot energy is being used to produce electricity this
would be a great evolution in electricity generation.
 PROBLEM STATEMENT
• Design and develop a prototype model of showing the concept of Train
axle power generation through magnetic coupling which will show the
working of application of electricity production by DC motor generator on
secondary shaft coupled using non-contact magnetic coupling with prime
mover axle shaft of railway locomotive or bogie.

• Also fabricate the model of the same which will show the working desired
by it using a dc motor generator by using its driving energy from main axle
of railway bogie through a magnetic coupling designed using permanent
magnets.
 OBJECTIVE

• To Design and develop a prototype model of showing the concept of train

axle power generation through magnetic coupling.

• To fabricate the model of the same which will show the working desired by
of railway electricity power generation through magnetic coupling.

• To test the model under different conditions to get electricity output from
DC motor generator.

• Provide an efficient and not disturbing method for power generation which
will not affect the normal working of railway axle.
 LITERATURE REVIEW
S PAPER AUTHOR PUBL REVIEW
R TITLE ISHI
N NG
O

1. Electricity Paidimukkul (Jan – This paper aims at production of electricity by using the concept of
a Bhanu the rotation of wind turbine due to the wind caused by the moving
through Feb. train and also by using an electrical power generation system. As
Train Chaitanya1, 2015) anyone living near railway tracks will tell you, speeding trains
Gedda generate quite a bit of wind as they whoosh past. The idea is to
Gowtham2 design a wind turbine that can be installed between the sleepers on a
track, and as the train passes overhead, the wind drives a turbine to
generate electricity.

2. POWER Sujata M. 2016 Many areas aren’t windy and having intermittency behavior of wind
GENERATIO Tupe1, is one of the big obstacle to the world wide application of wind
N THROUGH Dhanashri P. power generation .This paper attempts to explain the method of
WIND generating energy through moving train by using wind mill. The
CREATED BY Chavan2, method for generating electricity is by tapping wind pressure
MOVING Chhaya P. generated by moving train through windmill .The turbine converts
TRAIN Avhad3, A. wind energy into mechanical energy and this mechanical energy is
K. Pathak4 converted into electrical energy by using generating device. It will be
helpful to fulfill the increasing demand of electricity.
S PAPER AUTHOR PUBL REVIEW
R TITLE ISHIN
N G
O
3. Production Neeraj 2, This paper aims at production of electricity by using the concept of
of electricity Kumar, Decemb the rotation of wind turbine due to the wind caused by the moving
by using Venkatesh er 2013 train. Wind turbine is provided with ventilated casing to reduce the
large air pressure. The mouth of casing is provided with valve to
turbine Kumar control the wind flow. The blade is mounted on the roof of the train
mounted on Sharma and total mechanical support is provided .The electricity produced
train will run the various loads connected to the train cabin. The excess
power is stored in battery for further use.

4. Automatic Ashvini 2,FEB In our paper we are minimizing accident of level crossing between
Railway Sherwade 1, 2016 the railroads & highway. In this paper PIC16F877A microcontroller
Gate Control Ashwini is used to minimize the human effort & control the whole circuit.
Two types of sensors is used & output of the first IR sensor are
& Power Pawar 2, placed near to gate it receives the signal from arrival of the train then
Generation Bhagyashree send output signal to microcontroller. Microcontroller output to
Ghadge 3, motor driver then motor rotates in clockwise direction, then gate is
Deepika close. Second sensor is placed another side of gate those are sense
Srivastava departure of the train & send signal to microcontroller.
Microcontroller send signal to motor driver, motor rotates in
anticlockwise direction & gate is open.
 Magnet coupling
• Principles of operation.
The magnetic coupling works by using the power generated by
permanent magnets. No external power supply is needed. These are
permanent magnets not electro magnets.

The magnets are installed alternating between poles in a side by side

and opposing position as seen in the diagram. The main body of each
coupling half is of ferromagnetic material to aid the channeling of the
magnetic field correctly and therefore maximizing transmittable torque.
WORKING DIAGRAM
 WORKING
• The system used its driving energy through an input electric motor which
drives a shaft to show the rotational motion of the railway axle.
• The wheel is provided to show the working of railway wheel which also
stores the inertia energy of shaft which drives the system.
• In between the shaft a permanent magnetic coupling is provided which will
transfer through rotational energy from driving shaft to the DC motor
generator shaft.
• This coupling uses the disc coupling formed by two discs on who's
circumferences of it the permanent magnets are placed.
• The magnets implies the torque force onto exact other by magnetic force of
attraction and by thus when driving shaft is rotated by motor
simultaneously the generator shaft also starts moving due to magnetic
coupling.
• By thus we provide rotational motion to the DC motor generator which
will convert the rotational mechanical energy into electrical energy.
• Which is indicated by a LED which glows when electricity is produced by
generator motor.
• The whole construction is done on a base frame fabricated using L angle
mild steel channel.
• The magnetic disc coupling are also formed using mild steel circular
plates and permanent magnets are placed on periphery of it.
• The motors are placed at ends of shaft and fitted to base frame.
 COMPONENTS
Shafts:
•We can supply finished and semi-finished railway axle with different
dimensions for railway rolling stocks.
•shaft diameter D=15 mm.

Permanent magnetic disc coupling:

•Permanent magnetic coupling is provided which will transfer through
rotational energy from driving shaft to the motor generator shaft.

fig. magnetic coupling

LED: Used to indicate when electricity is produced by generator motor.

• Wheel:
• wheel is a circular component that is intended to rotate on an axle bearing.
• A wheel greatly reduces friction by facilitating motion by rolling together
with the use of axles.
• Specification:
• Tyre size: 90/100-10
• Rim size: 10 inch
• Brake type & size Drum 130mm
• DC motor:
• A DC motor is any of class of electrical machines that converts the direct
current electric power into mechanical power.
• It produce rotary motion; a linear motor directly produces force and
motion in a straight line.
• Features of 100RPM Center Shaft Metal Gear DC Motor
Battery(12v lead acid battery):

The batteries are used as a storage device for solar

energy which can be further converted into electrical
energy.
 CALCULATION
• Shafts:
• VOTAGE OF MOTOR=12V
• CURRENT OF MOTOR =3A
• Power =current*voltage
• =12*3=36W
• Input Power by DC motor = 36watt.
• SHAFT STRENGTH UNDER TORSIONAL LOAD
• The shafts are always subjected to fatigue load hence they must be calculated
for fatigue strength under combined bending and torsion loading. However, the
initial estimate of diameter is obtained from the torque that is transmitted by
the shaft. The bending moment variation along the length of the shaft is
established after fixing some structural features like distance between
supporting bearings and distance between points of application of forces and
bearings.
• Following notations will be used for shaft.
• d = diameter of shaft,
• Mt = torque transmitted by the shaft, = 15 Kgcm= 1.47 Nm.
• W= power transmitted by the shaft (W)
• N = rpm of the motor shaft = 100 rpm
• τs= permissible shearing stress,
• σb= permissible bending stress, and
• Mb = bending moment.
• Considering only transmission of torque by a solid shaft.
• The power transmitted by shaft and the torque in the shaft are related
as
• W= Mt* ω
• If W is in Watts and Mt in Nm.ω is angular velocity in rad/s and
equals 2πN/60
• W=2πNMt/60
• Mt= 30W/ πN...…eqn 1
• The shearing stress and the torque are related as
• τ = 16 Mt*103 / π*d3
• If Mt is in Nm and d in mm.
• Mt= π/16 (103 τd3 ) …………………………………eqn 2
• d3 = Mt*16 /π103 τ
• In Eq. (3) W is in Watt, τin N/mm2, N in rpm and d in mm.
• For calculating shaft diameter, d, we substitute the permissible value of
shearing stress in place of τ. Table below describes permissible values for
steel shaft under various service conditions, when the bending are much
smaller then torsional loads.
• Table: Allowable Shear Stress for Shafts
• So equation 3 becomes
• d3 = Mt*16 /π103 τ 
• Taking allowable shear stress for shafts under small loads in
coupling as τ= 8 MPa = 8*106 Pa
• d3 = Mt*16 /πτ 106
• d3 = 1.47*16 /π*8*106
• d3= 0.935 *10-6 m
• d= 0.0097 m = 9.7 mm
• Considering factor of safety as 1.5, the shaft size will be
• D= 1.5*d
• D= 1.5*9.7
• D= 13.5 mm.
• So selected shaft diameter closest to D= 13.5 mm is = D=15 mm.
• This is taken as 15 mm to add better safety and availability in market.
• So we take diameter of second shaft will also be 15 mm.
• Modern Magnet Materials:
• There are four classes of modern commercialized magnets, each based on
their material composition. Within each class is a family of grades with
their own magnetic properties. These general classes are:
• Neodymium Iron Boron
• Samarium Cobalt
• Ceramic
• Alnico
• Magnetic properties:
• Some important properties used to compare permanent magnets
are:remanence (Br)which measures the strength of the magnetic
fieldcoercivity (Hci)the material's resistance to becoming
demagnetizedenergy product (BHmax)the density of magnetic energyCurie
temperature (TC)the temperature at which the material loses its magnetism
• Neodymium magnets have higher remanence, much higher coercivity and
energy product, but often lower Curie temperature than other types.
Neodymium is alloyed with terbium and dysprosium in order to preserve
its magnetic properties at high temperatures. The table below compares the
magnetic performance of neodymium magnets with other types of
permanent magnets.
•Force is calculated by:
•F = 0.577 * B^2 * A
•Where B is the flux density in the gap in kG, and A is the magnet area in square m.
•For round or rectangles shapes, use current sheet calculations to estimate B in the gap,
or at the end of the magnet. These equations are available in under the Tools section of
the navigation bar on our Web site. They can also be found in our Reference and Design
Manual, available for download under our Engineering Support section.
•If the magnet is in contact with steel, double the magnet length since the steel will
mirror the magnet's properties. For round or rectangles some distance off a steel keeper,
use current sheet equations to calculate flux at half the separation distance. This is a
ballpark calculation and empirical values are usually higher.
•F = 0.577 * B^2 *A*N
•For Neodymium Iron Boron magnet
•B= 175 kJ/m3
•N= Number of magnets = 6
•A= area for 30 mm round magnet= π/4 D2 = 7.06*10-4m2
•F=0.577*1752*7.06*10-4*4
•F=49.9 N
1. Torque transmitted:
• Torque exerted by this magnetic force onto disc coupling is
calculated by,
• Torque = force*perpendicular distance
• Torque = force*radius of disc
• Disc diameter= 130 mm so radius will be R= 65 mm= 0.065 m
• Torque T = F*R
• T= 49.9*0.065
• T= 3.24 Nm.
• So the torque transmitted by the magnetic coupling is 3.24 Nm.
2.Power transmitted:
• The power transmitted by the magnetic coupling is calculated by,
• P= 2πNT/60 watt.
• P= 2*3.142*30*3.24/60
• P= 10.18 watt.
•Motor selection for wheels
•Given
•Diameter for SHAFT=15 mm
•Weight of SYSTEM is=15kg
•Torque required for motor
•Torque=force*length of link
•=0.55*9.81*100
•=1103.62 Nmm
•=1.103Nm
•=11.03kgcm
•So torque required for seeder motor is =15 kgcm
•Therefore we are selecting motor with 15kgcm torque.
•Power output of DC motor is =voltage *current
•=12*0.8
•=9.6 watt
•Power=2*pi*N*torque/60
•9.6=2*pi*N*1.103/60
•N=83.11rpm
•We are selecting motor with 100rpm.
 
SOFTWARE DESIGN
 ADVANTAGES
• Effective and eco friendly.
• No effect on ongoing system cause using non-contact method.
• Produced energy can be used or stored according to need.
• Due to use of magnetic non-contact coupling there is no friction / wear /
and heat production due to it hence power loss is very small.
• Production of electricity without any other external source.
• Conservation of electricity.
 APPLICATION
• For railway bogies, locomotives to produce electricity.

• This electricity can be used for lighting, water pumping and circulation and
HVAC systems in train etc.
 CONCLUSION
 We are using the principle of magnetism which transmits the rotational
mechanical energy of first shaft in equivalent rotational energy of second
shaft.
 Which can be converted into electrical by generator and can be stored in
batteries and used whenever and wherever required.
COST ESTIMATION
PROJECT PLAN
 REFERENCES
1] Kunhabdulla, Sajid PP, Praveen Merala, and Ashutosh Sahoo. "Power Generation from

Vibrations on the Sleepers beneath Railway Tracks for Railway Stations." International

Journal for Innovative Research in Science and Technology 1.3 (2014): 106-113.

[2] Mukunthan, S. "Train Wheel Electricity Generation."

[3] Chaitanya, Paidimukkula Bhanu, and Gedda Gowtham. "Electricity through Train."

[4] Ashvini Sherwade 1, Ashwini Pawar 2, Bhagyashree Ghadge 3, Deepika Srivastava. "

Automatic Railway Gate Control & Power Generation." International Journal of

Innovative Research in Science, Engineering and Technology, Vol. 5, Issue 2, Februray

2016.

[5] Bharathi, S., et al. "A Method for Generating Electricity by Fast Moving Vehicles."

Applied Mechanics and Materials. Vol. 110. Trans Tech Publications, 2012.
THANK YOU