Generation of Electricity by using Exhaust from Bike Silencer - MECHANICAL PROJECT REPORT FOR STUDENTS

 

CHAPTER-1

INTRODUCTION

 

            In recent years the scientific and public awareness on environmental and energy issues has brought in major interests to the research of advanced technologies particularly in highly efficient internal combustion engines. Viewing from the socio-economic perspective, as the level of energy consumption is directly proportional to the economic development and total number of population in a country, the growing rate of population in the world today indicates that the energy demand is likely to increase .Substantial thermal energy is available from the exhaust gas in modern automotive engines. Two-thirds of the energy from combustion in a vehicle is lost as waste heat, of which 40% is in the form of hot exhaust gas.

 

            The latest developments and technologies on waste heat recovery of exhaust gas from internal combustion engines (ICE). These include thermoelectric generators (TEG), Organic Rankine cycle (ORC), six-stroke cycle IC engine and new developments on turbocharger technology. Being one of the promising new devices for an automotive waste heat recovery, thermoelectric generators (TEG) will become one of the most important and outstanding devices in the future. A thermoelectric power generator is a solid state device that provides direct energy conversion from thermal energy (heat) due to a temperature gradient into electrical energy based on “Seebeck effect”. The thermoelectric power cycle, charge carriers (electrons) serving as the working fluid, follows the fundamental laws of thermodynamics and intimately resembles the power cycle of a conventional heat engine.One potential solution is the usage of the exhaust waste heat of combustion engines. This is possible by the waste heat recovery using thermoelectric generator. A thermoelectric generator converts the temperature gradient into useful voltage that can used for providing power for auxiliary systems such as air conditioner and minor car electronics.

 

Fig.1.1 World Marketed Energy used by Fuel Type 1980-2030

 

            Even it can reduce the size of the alternator that consumes shaft power. If approximately 6% of exhaust heat could be converted into electrical power, it will save approximately same quantity of driving energy. It will be possible to reduce fuel consumption around 10 %; hence AETEG systems can be profitable in the automobile industry. The number of vehicles (passenger and commercial vehicles) produced from 2005 to 2010 shows an overall increasing trend from year to year despite major global economic downturn in the 2008–2010 periods Note that China’s energy consumption in transportation sector is the lowest (13.5%) Although the country produced the highest number of vehicles in 2009 to 2010 as compared to the other countries.

 

            A number of irreversible processes in the engine limit its capability to achieve a highly balanced efficiency. The rapid expansion of gases inside the cylinder produces high temperature differences, turbulent fluid motions and large heat transfers from the fluid to the piston crown and cylinder walls. These rapid successions of events happening in the cylinder create expanding exhaust gases with pressures that exceed the atmospheric level, and they must be released while the gases are still expanding to prepare the cylinder for the following processes. By doing so, the heated gases produced from the combustion process can be easily channeled through the exhaust valve and manifold.

            The large amount of energy from the stream of exhausted gases could potentially be used for waste heat energy recovery to increase the work output of the engine. Consequently, higher efficiency, lower fuel consumption by improving fuel economy, producing fewer emissions from the exhaust, and reducing noise pollutions have been imposed as standards in some countries. Hatazawa et al., Stabler, Taylor, Yu and Chau and Yang stated that the waste heat produced from thermal combustion process generated by gasoline engine could get as high as 30–40% which is lost to the environment through an exhaust pipe.

 

            In internal combustion engines a huge amount of energy is lost in the form of heat through the exhaust gas. Conklin and Szybist investigated that the percentage of fuel energy converted to  useful work only 10.4% and also found the thermal energy lost through exhaust gas about 27.7%. The second law (i.e., exergy) analysis of fuel has been shown that fuel energy is converted to the brake power about 9.7% and the exhaust about 8.4% as shown in Fig. 3. In another research the value of exhaust gases mentioned to be 18.6% of total combustion energy. It is also found that by installing heat exchanger to recover exhaust energy of the engine could be saved up to 34% of fuel saving

 

            For example, the heat of the car's exhaust can be used to warm the engine coolant to keep the engine running warm, even when the motor has been turned off for a significant length of time. A vehicle's exhaust can actually be used to generate electricity. Although these technologies can be used in any car, truck or SUV with an internal combustion engine, they're particularly important to hybrid vehicles, which need to produce maximum fuel efficiency and minimal emissions. The potential cost savings, improved energy efficiency and broad application of such technology is enormous, experts say. The new systems now being perfected at OSU should be able to use much of that waste heat either in cooling or the production of electricity.

 

 

 

CHAPTER-2

LITERATURE SURVEY

 

            Power Generation using Two-Wheeler Silencer by J. Emeema, C. Lakshmi this paper explains the power generation form exhaust gases of vehicle with help of turbine setup, which consists of turbine made of aluminium because it has high heat conductivity, a dynamo, battery to store generated energy, inverter, on-off switch, a led indicator. by conducting test and observation the author calculates the turbine speed, velocity and the turbine power. The project was successfully carried out on pulsar 150 with the turbine setup to generate electrical energy from exhaust gases of bike.Kranthi Kumar Guduru, Yakoob Kol ipak and Shanker. B, N. Suresh This paper explains that the large amount of power is getting wasted from vehicle which is splites into categories such as effective power mobility and accessories , friction and parasitic losses ,coolant and exhaust gases of large amount of energy is wasted in form of exhaust gases .which can be recovered by using exhaust power generation which is simple in setup , it can be used for both two wheelers and four wheelers, with help of turbine , battery ,dynamo , nozzle setup power is generated. The principal used is converting kinetic energy into electrical energy. which will be used to charge the battery and for other electrical accessories.

 

            Generation of Electricity by Using Exhaust from Bike by S. Vijaya Kumar, Amit Kumar Singh, Athul Sabu, Mohamed Farhan. In this paper author studied different ways to recover the exhaust heat energy wasting form vehicle silencer. methods to recover waste energy are turbine dynamo setup, thermoelectrical generator. the experiment is carried out by placing a turbine in path of exhaust silencer which is connected to dynamo. Depending upon the flow of exhaust gases the turbine will rotate and power will be producing with help of dynamo. The experiment is successfully tested and implanted. Study and performance analysis of charging vehicle battery using bike exhaust gas by K. Kumaravel, P. Balashanmugam, and G. Balasubramanian, in this paper they had done different studies on different aspects of producing electrical energy from exhaust gases.

            They had taken the practical inputs using different ways of power generation and studied their outputs with the problem occurs on different engines.

 

            Engine battery super charging from exhaust gas by S. Pratheebha, in this paper author told us about different strategies for power age from fumes gas of vehicle utilizing dynamo, turbine, thermoelectric generator. setting a turbine in the way of exhaust in the silencer. A motor is likewise positioned in the body of the vehicle. The turbine is associated with a dynamo, which is utilized to produce power. Contingent on the wind current the turbine will begin pivoting, and afterward the dynamo will likewise begin to turn. A dynamo is a gadget which is utilized to change over the motor energy into electrical energy. The created power is put away to the battery. It very well may be put away in the battery after correction.

 

            Nonetheless, in this day and age of streamlining fuel utilization and attempting to recover each watt of force going unused in the vehicle, methods to recover power are significant. This work focuses light on a strategy which has gigantic guarantee in recovering waste energy from the exhaust of a vehicle. Through this work, a most extreme force yield of around 15W was gotten from the turbine arrangement. With appropriate examination in the field, we might have the option to deliver such a lot of force from different wellsprings of the vehicle that this force might be utilized as a helper driving hotspot for itself.

 

            Generating Electricity by Using Exhaust Gas by Venkatesh. J, Karthik Kumar. R, Karthikeyan. G, Kavin. R, Keerthi raja S.V.G. This paper explains how we can produce power utilizing fumes gas. The turbine utilizes squander fumes gas and produce power. We use silencer for both force age and provincial jolt. The turbine produces power and it is put away utilizing battery. Both turbine and battery are painstakingly positioned in their individual spots. The put away power can be utilized for our particular purposes. Additional Power Generation from the Exhaust Gasof Diesel Engine by Bottoming Rankine Cycle by Shekh Nisar Hossain and Saiful Bari. The fumes of a diesel motor contain 40% of the information energy and normally this energy is squandered by removing to the climate.

            The general effectiveness of the diesel motor can be improved by recuperating this waste warmth to create extra force by turbine utilizing Rankine Cycle. In this task, explore was directed to appraise accessible energy in the fume’s gas of a diesel motor. From the momentum research the accompanying ends are drawn: Heat recuperation for a motor is more compelling at higher force of the motor, Counter stream shell and cylinder heat exchanger can recuperate heat all the more productively.

 

            Power Generation from Exhaust Gas of an IC Engine by Impha Y D, Mahammad Yunus C, Ajaygan K, Mustaqeem Raza, Mohammed Imran, Harsha Raj K From this undertaking, it has been distinguished that there are enormous possibilities of energy investment funds using waste warmth recuperation advances. Squander heat recuperation involves catching and reusing the waste warmth from inside burning motor and utilizing it for warming or creating mechanical or electrical work. It would likewise assist with perceiving the improvement in execution and emanations of the motor if these innovations were embraced by the car producers. The investigation additionally recognized the possibilities of the advances when joined with different gadgets to expand potential energy effectiveness of the vehicles.

 

            Power generation from waste of IC engines by Ataur Rahman, Fadhilah Razzak, Rafia Afroz, Mohiuddin AKM, MNA Hawlader. Reusing the waste heat from internal combustion engine and using it for electrical work. Generation of electricity from the high temperature difference can be done by using thermoelectric system and it can available at affordable cost.

 

            Convert exhaust gas into electrical energy. The temperature difference from hot surface to coolant surface resulted in greater voltage and current was increased. Finally, it is concluded that the production of electrical energy from exhaust gases depends on temperature difference and number of TEG modules.

 

CHAPTER-3

PROBLEM DEFINITION

 

            The primary objective is to explore the feasibility of harnessing energy from the exhaust gases of a bike silencer to generate electricity. This project aims to address the issue of wasted energy in conventional internal combustion engines and utilize it for power generation.

 

3.1 Existing System:

            Describe the current state of conventional internal combustion engines used in motorcycles and the typical operation of their exhaust systems. Explain how the energy contained in the exhaust gases is currently wasted and dissipated into the environment.

 

3.2 Proposed System:

            Introduce the concept of capturing the wasted energy from the bike's exhaust and converting it into electrical energy. Explain the idea of using a system that can recover heat energy from the exhaust gases and convert it into mechanical or electrical power.

 

Chapter-4

OBJECTIVES

 

Clearly state the objectives of the project, which may include:

 

• Designing and developing an efficient heat recovery system for bike exhaust.

 

• Converting the recovered heat energy into electrical power.

 

• Evaluating the performance and efficiency of the proposed system.

 

• Assessing the economic feasibility and potential environmental benefits.

 

Chapter-5

METHODOLOGY

 

            Now a day in automobile field many new innovating concepts are being developed. In this paper by using power from vehicle exhaust for generation electricity which can be stored in battery for the later consumption. In this project, we are demonstrating a concept of generating power in a moving vehicle by the usage of turbines. Here we are placing a turbine in the path of exhaust in the silencer. An engine is also placed in the chassis of the vehicle. The turbine is connected to a dynamo, which is used to generate power. Depending upon the airflow the turbine will start rotating, and then the dynamo will also starts to rotate. A dynamo is a device which is used to convert the kinetic energy into electrical energy. The generated power is stored to the battery. It can be stored in the battery after rectification. The rectified voltage can be inverted and can be used in various forms of utilities.

 

Hardware Description:

Motor as a Generator: Before the connection between magnetism and electricity was discovered, electrostatic generators were used. They operated on electrostatic principles. Such generators generated very high voltage and low current. They operated by using moving electrically charged belts, plates, and disks that carried charge to a high potential electrode. The charge was generated using either of two mechanisms:

• Electrostatic induction
• The turboelectric effect, where the contact between two insulators leaves them charged.

 

Motor as a Generator

            A motor-generator (an M-G set or a dynamotor for dynamo-motor) is a device for converting electrical power to another form. Motor-generator sets are used to convert frequency, voltage, or phase of power. They may also be used to isolate electrical loads from the electrical power supply line.

            Large motor-generators were widely used to convert industrial amounts of power while smaller motor-generators (such as the one shown in the picture) were used to convert battery power to higher DC voltages. Low-powered devices such as vacuum tube mobile radio receivers did not use motor-generators. Instead, they would typically use an inverter circuit consisting of a vibrator (a self-exciting relay) and a transformer to produce the B+ voltages required for the vacuum tubes.

 

            Typically the motor coils are driven from a commutator on one end of the shaft, when the generator coils output to another commutator on the other end of the shaft. The entire rotor and shaft assembly is smaller in size than a pair of machines, and may not have any exposed drive shafts. In electricity generation, an electric generator is a device that converts mechanical energy to electrical energy. A generator forces electric current to flow through an external circuit. The source of mechanical energy may be a reciprocating or turbine steam engine, water falling through a turbine or waterwheel, an internal combustion engine, a wind turbine, a hand crank, compressed air, or any other source of mechanical energy. Generators provide nearly all of the power for electric power grids.

 

Electromagnetic Generators Dynamo:

            A dynamo is an electrical generator that produces direct current with the use of a commutator. Dynamos were the first electrical generators capable of delivering power for industry, and the foundation upon which many other later electric-power conversion devices were based, including the electric motor, the alternating-current alternator, and the rotary converter. Today, the simpler alternator dominates large scale power generation, for efficiency, reliability and cost reasons. A dynamo has the disadvantages of a mechanical commutator. Also, converting alternating to direct current using power rectification devices (vacuum tube or more recently solid state) is effective and usually economic.

 

Alternator:

            Without a commutator, a dynamo becomes an alternator, which is a synchronous singly fed generator. Alternators produce alternating current with a frequency that is based on the rotational speed of the rotor and the number of magnetic poles.

            Automotive alternators produce a varying frequency that changes with engine speed, which is then converted by a rectifier to DC. By comparison, alternators used to feed an electric power grid are generally operated at a speed very close to a specific frequency, for the benefit of AC devices that regulate their speed and performance based on grid frequency. Some devices such as incandescent lamps and ballast-operated fluorescent lamps do not require a constant frequency, but synchronous motors such as in electric wall clocks do require a constant grid frequency.

 

LED

            A light-emitting diode (LED) is a semiconductor light source. LEDs are used as indicator lamps in many devices, and are increasingly used for lighting. Introduced as a practical electronic component in 1962, early LEDs emitted low-intensity red light, but modern versions are available across the visible, ultraviolet and infrared wavelengths, with very high brightness. The internal structure and parts of a led are shown in figures 3.15 and 3.16 respectively.

 

 

Silencer:

            A muffler is a device for reducing the amount of noise emitted by the exhaust of an internal combustion engine. Mufflers are installed within the exhaust system of most internal combustion engines, although the muffler is not designed to serve any primary exhaust function.

 

                        The muffler is engineered as an acoustic soundproofing device designed to reduce the loudness of the sound pressure created by the engine by way of Acoustic quieting. The majority of the sound pressure produced by the engine is emanated out of the vehicle using the same piping used by the silent exhaust gases absorbed by a series of passages and chambers lined with roving fiberglass insulation and/or resonating chambers harmonically tuned to cause destructive interference wherein opposite sound waves cancel each other out. An unavoidable side effect of muffler use is an increase of back pressure which decreases engine efficiency. This is because the engine exhaust must share the same complex exit pathway built inside the muffler as the sound pressure that the muffler is designed to mitigate.

 

Analysis of the Exhaust System in an Average Car

            Exhaust system components are designed for a specific engine. The pipe diameter, component length, catalytic converter size, muffler size, and exhaust manifold design are engineered to provide proper exhaust flow, silencing, and emission levels on a particular engine. In this section, I will go over the function and specifics of each component.

 

Wind Turbine:

            A wind turbine is a device that converts kinetic energy from the wind, also called wind energy, into mechanical energy; a process known as wind power. If the mechanical energy is used to produce electricity, the device may be called a wind turbine or wind power plant. If the mechanical energy is used to drive machinery, such as for grinding grain or pumping water, the device is called a windmill or wind pump. Similarly, it may be referred to as a wind charger when used for charging batteries. The result of over a millennium of windmill development and modern engineering, today's wind turbines are manufactured in a wide range of vertical and horizontal axis types. The smallest turbines are used for applications such as battery charging or auxiliary power on boats; while large grid-connected arrays of turbines are becoming an increasingly important source of wind power-produced commercial electricity.

 

Horizontal Axis:

            Horizontal-axis wind turbines (HAWT) have the main rotor shaft and electrical generator at the top of a tower, and must be pointed into the wind. Small turbines are pointed by a simple wind vane, while large turbines generally use a wind sensor coupled with a servo motor. Most have a gearbox, which turns the slow rotation of the blades into a quicker rotation that is more suitable to drive an electrical generator. Since a tower produces turbulence behind it, the turbine is usually positioned upwind of its supporting tower. Turbine blades are made stiff to prevent the blades from being pushed into the tower by high winds. Additionally, the blades are placed a considerable distance in front of the tower and are sometimes tilted forward into the wind a small amount.

 

Blades

            Lifts and rotates when wind is blown over them, causing the rotor to spin. Most turbines have either two or three blades.

 

            Wind direction determines the design of the turbine upwind turbines—like the one shown here face into the wind while downwind turbines face away.

 

Rechargeable Battery

            A rechargeable battery, storage battery, or accumulator is a type of electrical battery. It comprises one or more electrochemical cells, and is a type of energy accumulator. It is known as a secondary cell because its electrochemical reactions are electrically reversible. Rechargeable batteries come in many different shapes and sizes, ranging from button cells to megawatt systems connected to stabilize an electrical distribution network. Several different combinations of chemicals are commonly used, including: lead–acid, nickel cadmium (NiCd), nickel metal hydride (NiMH), lithium ion (Li-ion), and lithium ion polymer (Li-ion polymer).

Chapter-6

WORKING PRINCIPLE

 

Thermoelectric Generators (TEGs): TEGs can convert heat into electricity using the principle of the Seebeck effect. When there is a temperature difference between two dissimilar conductive materials, a voltage is generated across them. If the bike's exhaust could be significantly hotter than the surrounding environment, TEGs could potentially be used to harness some of the waste heat and convert it into electricity.

 

Turbines and Generators: Some vehicles, especially hybrid and electric cars, use regenerative braking systems to convert kinetic energy into electricity when braking. This principle might not directly apply to a bike's exhaust, but it's a common way to recapture energy in certain vehicles.

 

Steam Engines: In the past, steam engines were used to convert heat energy into mechanical energy, which could then be used to generate electricity. While not practical for bikes, this method was used in larger-scale power generation in some industries.

 

Stirling Engines: Stirling engines can convert heat into mechanical work and then drive an electricity generator. However, their efficiency is generally low, and they are not commonly used for this purpose.

 

Thermophotovoltaic (TPV) Cells: These devices use heat to generate light, which is then converted into electricity using photovoltaic cells. TPV technology is still in its early stages and has not been widely adopted.

 

            It's worth mentioning that attempting to generate electricity from a bike's exhaust can be hazardous, both in terms of potential damage to the bike's engine and the risk of exposure to toxic exhaust fumes. Additionally, any modifications to a vehicle should be done with proper expertise and consideration of local regulations.

 

            If there have been any recent developments or breakthroughs beyond my knowledge cutoff, I wouldn't be aware of them. Therefore, I recommend conducting further research to see if there have been any advancements or new technologies related to this topic.

 

            The fig.6.1 shows block diagram which gives you the overview of the proposed system. The brief description given bellow.

 

Block Diagram Description:

 

 

Project description with implementation issues

 

Components and its Functions:

            The generations of electricity using the flow or velocity of vehicle exhaust gas of the following components to full fill the requirements of complete operation of the machine. 1. Dynamo 2. Turbine 3. Battery 4. Silencer

 

TURBINE:

            A steam turbine is a mechanical device that extracts thermal energy from pressurized steam, and converts it into rotary motion. It has almost completely replaced the reciprocating piston steam engine primarily because of its greater thermal efficiency and higher power-to-weight ratio. Because the turbine generates rotary motion, it is particularly suited to be used to drive an electrical generator – about 90% of all electricity generation in the United States is by use of steam turbines.

DYNAMO:

            Dynamo is an electrical generator. This dynamo produces direct current with the use of a commutator. Dynamo were the first generator capable of the power industries.The dynamo uses rotating coils of wire and magnetic fields to convert mechanical rotation into a pulsing direct electric current. A dynamo machine consists of a stationary structure, called the stator, which provides a constant magnetic field, and a set of rotating windings called the armature which turn within that field. On small machines the constant magnetic field may be provided by one or more permanent magnets; larger machines have the constant magnetic field provided by one or more electromagnets, which are usually called field coils.

 

            The commutator was needed to produce direct current. When a loop of wire rotates in a magnetic field, the potential induced in it reverses with each half turn, generating an alternating current. However, in the early days of electric experimentation, alternating current generally had no known use. The few uses for electricity, such as electroplating, used direct current provided by messy liquid batteries. Dynamos were invented as a replacement for distance measurement, they are also used in ultrasonic material testing (to detect cracks, air bubbles, and other flaws in the products), Object detection, position detection, ultrasonic mouse, etc. batteries. The commutator is a set of contacts mounted on the machine's shaft, which reverses the connection of the windings to the external circuit when the potential reverses, so instead of alternating current, a pulsing direct current is produced.

 

BATTERY:

            In our project we are using secondary type battery. It is rechargeable type. A battery is one or more electrochemical cells, which store chemical energy and make it available as electric current. There are two types of batteries, primary (disposable) and secondary (rechargeable), both of which convert chemical energy to electrical energy.                        

SILENCER:

            Due to atmosphere protection and to prevent bad content of gases, normally silencer is provided to any system to which combustion take place or that generates the exhaust gases. 

            When an engine runs, high pressure exhaust gas is released. This causes a pressure wave in the air causing and explosion very fast to form a steady noise. These are two group low frequency from 50 HZ to 500 HZ. To reduce the noise, the engine exhaust is connect to exhaust pipe to the silencer it is also called as muffler in automobile vehicles. In the muffler the gases or the polluted air are allowed to expand gradually and to cool. There are various type

 

WELDING PROCESSES ARE CLASSIFIED INTO TWO MAJOR GROUPS:

            Fusion welding: In this process, base metal is melted by means of heat. Often, in fusion welding operations, a filler metal is added to the molten pool to facilitate the process and provide bulk and strength to the joint. Commonly used fusion welding processes are: arc welding, resistance welding, oxyfuel welding, electron beam welding and laser beam welding.

 

            Solid-state welding: In this process, joining of parts takes place by application of pressure alone or a combination of heat and pressure. No filler metal is used. Commonly used solid-state welding processes are: diffusion welding, friction welding, ultrasonic welding.

 

            Arc welding and similar processes Arc welding is a method of permanently joining two or more metal parts. It consists of combination of different welding processes wherein coalescence is produced by heating with an electric arc, (mostly without the application of pressure) and with or without the use of filler metals depending upon the base plate thicknessA homogeneous joint is achieved by melting andfusing the adjacent portions of the separate parts. The final welded joint has unit strength approximately equal to that of the base material. The arc temperature is maintained approximately 4400°C.

 

            A flux material is used to prevent oxidation, which decomposes under the heat of welding and releases a gas that shields the arc and the hot metal.The second basic method employs an inert or nearly inert gas to form a protective envelope around the arc and the weld. Helium, argon, and carbon dioxide are the most commonly used gases.

SHIELDED-METAL ARC (SMAW) OR STICK WELDING

            This is an arc welding process wherein coalescence is produced by heating the work piece with an electric arc setup between a flux-coated electrode and the work piece. The electrode is in a rod form coated with flux. Figure M6.1.1 illustrates the process.

 

 

Figure Shielded – Metal Arc (SMAW)

 

SUBMERGED ARC WELDING (SAW)

            This is another type of arc welding process, in which coalescence is produced by heating the work piece with an electric arc setup between the bare electrode and the work piece. Molten pool remains completely hidden under a blanket of granular material called flux. The electrode is in a wire form and is continuously fed from a reel. Movement of the weld gun, dispensing of the flux and picking up of surplus flux granules behind the gun are usually automatic. Flux-Cored Arc Welding (FCAW)

 

FLUX-CORED ARC WELDING (FCAW)

            This process is similar to the shielded-arc stick welding process with the main difference being the flux is inside the welding rod. Tubular, coiled and continuously fed electrode containing flux inside the electrode is used, thereby, saving the cost of changing the welding. Sometimes, externally supplied gas is used to assist in shielding the arc.

GAS-METAL ARC WELDING (GMAW)

            In this process an inert gas such as argon, helium, carbon dioxide or a mixture of them are used to prevent atmospheric contamination of the weld. The shielding gas is allowed to flow through the weld gun. The electrode used here is in a wire form, fed continuously at a fixed rate. The wire is consumed during the process and thereby provides filler metal. This process is illustrated in Figure

 

GAS-TUNGSTEN ARC WELDING (GTAW)

            This process is also known as tungsten–inert gas (TIG) welding. This is similar to the GasMetal Arc Welding process. Difference being the electrode is non consumable and does not provide filler metal in this case. A gas shield (usually inert gas) is used as in the GMAW process. If the filler metal is required, an auxiliary rod is used

 

Figure Plasma Arc Welding (PAW)

 

PLASMA ARC WELDING (PAW)

            This process is similar to TIG. A non-consumable electrode is used in this process. Arc plasma is a temporary state of gas. The gas gets ionized after the passage of electric current and becomes a conductor of electricity. The plasma consists of free electrons, positive ions, and neutral particles. Plasma arc welding differs from GTAW welding in the amount ofionized gas which is greatly increased in plasma arc welding, and it is this ionized gas that provides the heat of welding. This process has been illustrated in Figure M6.1.3.

 

OXYFUEL GAS WELDING (OFW)

            This process is also known as oxy-acetylene welding. Heat is supplied by the combustion of acetylene in a stream of oxygen. Both gases are supplied to the torch through flexible hoses. Heat from this torch is lower and far less concentrated than that from an electric arc.

 

RESISTANCE WELDING

            Resistance welding is a group of welding process in which coalescence is produced by the heat obtained from the resistance of the work to the flow of electric current in a circuit of which the work is a part and by the application of pressure. No filler metal is needed in this process.

 

ELECTRON-BEAM WELDING

            (EBW) Electron beam welding is defined as a fusion welding process wherein coalescence is produced by the heat obtained from a concentrated beam of high velocity electron. When high velocity electrons strike the workpiece, kinetic energy is transformed into thermal energy causing localized heating and melting of the weld metal. The electron beam generation takes place in a vacuum, and the process works best whenthe entire operation and the workpiece are also in a high vacuum of 10-4torr or lower. However, radiations nameray, infrared and ultraviolet radiation generates and the welding operator must be protected

 

LASER BEAM WELDING (LBW)

            Laser beam welding is defined as a fusion welding process and coalescence is achieved by utilizing the heat obtained from a concentrated coherent light beam and impinging upon the surface to be joined. This process uses the energy in an extremely concentrated beam of coherent, mono-chromatic light to melt the weld metal. This process is illustrated in Figure M6.1.4

 

 

Figure: Laser-Beam Welding

 

FRICTION WELDING (FRW)

            In friction welding (solid state welding process) coalescence is produced by utilizing the heat obtained from the mechanically induced rotating motion between the rubbing surfaces. When the temperature at the interface of the two parts is sufficiently high, the rotation is stopped and increased axial force is applied. This fuses the two parts together. The rotational force is provided through a strong motor or a flywheel. In the latter case the process may be called inertia welding.

 

OTHER WELDING PROCESSES

Other processes used in the industry are following:

1. Diffusion bonding (DB): Parts are pressed together at an elevated temperature below the melting point for a period of time.
2. Explosion welding (EXW): The parts to be welded are driven together at an angle by means of an explosive charge and fuse together from the friction of the impact.
3. Ultrasonic welding (USW) for metals: This process utilizes transverse oscillation of one part against the other to develop sufficient frictional heat for fusion to occur.
4. Electro slag (ESW) and Electro gas (EGW) processes: In these processes a molten pool of weld metal contained by copper “shoes” is used to make vertical butt welds in heavy plate.

 

CHAPTER-7

APPLICATIONS

 

            Rechargeable batteries are used for automobile starters, portable consumer devices, light vehicles (such as motorized wheelchairs, golf carts, electric bicycles, and electric forklifts), tools, and uninterruptible power supplies. Emerging applications in hybrid electric vehicles and electric vehicles are driving the technology to reduce cost and weight and increase lifetime. Traditional rechargeable batteries have to be charged before their first use; newer low self-discharge NiMH batteries hold their charge for many months, and are typically charged at the factory to about 70% of their rated capacity before shipping.

 

            Grid energy storage applications use rechargeable batteries for load leveling, where they store electric energy for use during peak load periods, and for renewable energy uses, such as storing power generated from photovoltaic arrays during the day to be used at night. By charging batteries during periods of low demand and returning energy to the grid during periods of high electrical demand, load-leveling helps eliminate the need for expensive peaking power plants and helps amortize the cost of generators over more hours of operation.

 

            Generation of Electricity by Using Exhaust from Bike by S.Vijaya Kumar, Amit Kumar Singh, Athul Sabu and Mohamed Farhan.P[1]:- According to their study, it has been identified that there are large potentials of energy savings through the use of waste heat recovery technologies. Waste heat recovery entails capturing and reusing the waste heat from internal combustion engine and using it for heating or generating mechanical or electrical work Study and performance analysis of charging vehicle battery using bike exhaust gas by K. Kumaravel, P. Balashanmugam, and G. Balasubramanian[2], They had done different studies according to their practical inputs. They had  approached the problem with different engine RPM. Practically for different engine speeds for different turbine power output were observed.

 

            Power Generation by Exhaust Gases On Diesel Engine by Kranthi Kumar Guduru, Yakoob Kolipak, Shanker. B and N. Suresh[3]:-. Waste heat recovery entails capturing and reusing the waste heat from internal combustion engine and using it for heating or generating mechanical or electrical work. It would also help to recognize the improvement in performance and emissions of the engine if these technologies were adopted by the automotive manufacturers.

CHAPTER-8

CONCLUSION

 

            The project  - Power Generation Using Exhaust Gases‖ was designed such that which makes use of silencer for power generation and also for rural electrification. The system was also used to control the devices. Integrating features of all the hardware components used have been developed in it. Presence of every module has been reasoned out and placed carefully, thus contributing to the best working of the unit. Secondly, using highly advanced IC’s with the help of growing technology, the project has been successfully implemented. Thus the project has been successfully designed and tested.

 

Future Scope

            Power Generation Using Exhaust Gases‖ is mainly intended to design a silencer based energy generation system based inverter. Air blowers generally use centrifugal force to propel air forward. Inside a centrifugal air blower is a wheel with small blades on the circumference and a casing to direct the flow of air into the center of the wheel and out toward the edge. The design of the blades will affect how the air is propelled and how efficient the air blower is. The paper makes use of a Silencer Setup, turbine and DC Generator. The energy obtained is stored to a battery. The battery supply is fed to pulse generator and in turn to a MOSFET which is capable of generating ON/OFF pulses of different frequencies. This is fed to a step up transformer to generate a low voltage AC. This AC is fed to electrical appliance.

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