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Project report on treadmill cycle

Abstract
This project continued previous work modifying a treadmill to better fit the needs of elderly
users. The project modified four aspects of a stock treadmill. The first modification was the
addition of a handrail system for increased safety. The second was a speed reduction mechanism
to allow for finer control. The third was a user interface tailored to the difficulties that present
with aging. The fourth was a new walking surface to absorb more impact than the original
surface.
This research work is aimed at converting the lost energy we expend doing exercise into
useful work. It is such that is designed to meet both human and nature’s need of keeping fit as
well as Generation of Electricity without of gas into the atmosphere respectively thereby making
it both user and environmental friendly.
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1 INTRODUCTION
1 The objective of this project was to continue work on modifying a treadmill to better fit
the needs of elderly users. Previous work on this subject includes an MQP where the
group identified these needs and modified a stock treadmill to better meet them. Based on
a survey of local senior citizens, they determined that a treadmill would be the best
machine to modify. They attempted to soften the impact force users experienced. They
also constructed handrails for added support and safety. Another modification that they
made was altering the motor control circuit to allow it to run at lower speeds. The final
modification was a new user interface tailored to the specific needs of elderly users. After
constructing a working prototype they performed clinical tests, asking elderly persons to
use the treadmill and comment on its features. Based on these results, we modified a new
treadmill to address users concerns with the original prototype.
2 Unfortunately, the prototype from the previous project was improperly stored after the
completion of the project. We therefore had to start anew with a different treadmill. This
was not a major setback however, since our final designs were significantly different
from the first prototype. Our design focused on the four major objectives but
3 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. Most of the people do exercise worldwide. Different
types of machines are used for exercise. These machines have handy operations. In
manual exercise machines muscle power goes waste during exercise. Anyways this
power which otherwise goes waste during exercise may be used by converting it into any
other form of energy. With the technological advancement across the globe, the demand
for energy is drastically increasing. The power generation is also increasing and most of
the energy generation plants are using fossil fuels which bring up many adverse effects.
Hence there is a need of alternative methods of power generation. Inventions are going
on worldwide for generating power through alternative methods. A treadmill
manufacturing company wood way manufactured a treadmill which generates power for
display and can even be used for
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4 The handrails constructed by the previous project were unnecessarily large and fairly
ineffective. They consisted of metal bars supported by 2x4 and 4x4 wooden beams. This
structure was very difficult to move, and it significantly increased the
5 The main Moto to do this project to convert the waste energy to the useful way
6 A treadmill is an exercising machine for running while still stationary. It is such that is
designed to improve the health conditions of man. But the idea of tapping the energy
expended doing this work is something of interest that we want to harness.
7 Motor Generator set are devices use to Generate electricity converting to mechanical energy.
The bicycle chain and sprockets was employed during the course of this development to
aid in transfer of motion. This is because of some advantages it poses over the spring and
bevel gear mechanisms which shall be decisively dealt with in the later part of this work.
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2 LITERATURE REVIEW
A K Katiyar, S T Murtaza& S Ali has conclude this treadmill with Electricity Generator
is useful for such areas where
electricity is not available and also Electrical energy can be saved by using this manual treadmill
with Electricity Generator.
Harsh Mankodi has concluded a treadmill based human power generator was developed
using an Electromagnetic dynamo
generator coupled to a manual treadmill’s flywheel. The final circuit delivering power to a heavy
duty battery was found to be
able to deliver 140 W peak for a short period of time.
For generation of energy by using treadmill we have to use manual treadmill to save energy and to minimize cost.

[1] Harsh Mankodi, “Analysis of a Treadmill Based Human Power Electricity Generator”,
Submitted under the supervision of Prof. Rusen Yang to the University Honors Program at the
University of Minnesota-Twin Cities in partial fulfillment of the requirements for the degree of
Bachelor of Mechanical Engineering, cum laude. June 30, 2012.
[2] “Design of Manual Treadmill with Electricity Generator for Energy Saving”, Shamshad Ali,
Assistant Professor Mechanical Engineering Section, University Polytechnic, A.M.U., Aligarh
(U.P.) India Syed Tariq Murtaza, Associate Professor Department of Physical Education, A.M.U.,
Aligarh (U.P.) India. Ashish Kumar Katiyar, Research Scholar Dept. of Physical Education, A.M.U,
Aligarh (U.P.) India.
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3. THEORY
3.1 Objectives of the work:
The following are the objectives of the work:
a. To make a bending machine to bend metal sheets.
b. To make on simple working principle.
c. To reduce the time for operation.
d. To make in minimum cost.
e. To produce a bending machine which can be carried from one place to another,
f. To produce a bending machine with low cost
g. To produce a bending machine which can bend both bars and hollow circular sections
and
h. To fit an adjustable stand on the machine
3.2 BICYCLE CHAINS AND SPROCKETS:
A bicycle chain is a roller chain that transfers power from the pedals to the drive-wheel of a
bicycle, thus propelling it. Most bicycle chains are made from plain carbon or alloy steel, but
some are chrome-plated or stainless steel to prevent rust, or simply for aesthetics. Before the
safety bicycle, bicycles did not have chains and the pedals were typically attached directly to the
drive-wheel, thus limiting top speed by the diameter of the wheel and resulting in designs with
front wheels as large as possible. Various linkage mechanisms were invented to raise the
effective gear ratio, but with limited success. Using chain drive allowed the mechanical
advantage between the drive and driven sprockets to determine the maximum speed, thereby
enabling manufacturers to reduce the size of the driving wheel for safety. It also allowed for the
development of variable gearing, allowing cyclists to adjust their gearing to the difficulty of the
terrain, on the fly.

EFFICIENCY OF CHAIN/SPROCKET MECHANISM

A bicycle chain can be very efficient: one study reported efficiencies as high as 98.6%. The
study, performed in a clean laboratory environment, found that efficiency was not greatly
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affected by the state of lubrication. A larger sprocket will give a more efficient drive,
reducing the movement angle of the links. Higher chain tension was found to be more 10 v
bicycle chain can be very efficient: one study reported efficiencies as high as 98.6%. The study,
performed in a clean laboratory environment, found that efficiency was not greatly affected by
the state of lubrication. A larger sprocket will give a more efficient drive, reducing the
movement angle of the links. Higher chain tension was found to be more 10 efficient: "This is
actually not in the direction you'd expect, it was based simply on friction". Chains are mostly
used to transmit motion from one shaft to another.

Battery
An electric battery is a device consisting of one or more electrochemical cells with external
connections provided to power electrical devices. When a battery is supplying power, its
positive terminal is the cathode while its negative terminal is the anode.
iii. Charge controller
Charge controller has basic function is that it control the source which is to be active or inactive.
It simultaneously charge battery and also gives power to the load. The controller has over-charge
protection, short-circuit protection, pole confusion protection and automatic dump-load function.
It also the function is that it should vary the power as per the load demand. It add the both the
power so that the load demand can fulfill. And when power is not generating it should extract
power from battery and give it to the load.

iv. Battery Bank

We have to choose battery bank size per the load requirement so that it should fulfill the
requirement of load for calculating the battery bank size we need to find following data
1. Find total daily use in watt-hour (Wh).
2. Find total back up time of the battery
For increase in battery bank size we need to connect cell in series so that we can get the larger
battery bank size.
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v. Inverter
We have to choose greater rating inverter than the desired rating .The pure sign wave inverter is
recommended in other to prolong the lifespan of the inverter. Inverter is need to convert DC
power into AC power. As our load working on the AC supply so we need to convert DC power.
The input voltage Output voltage and frequency, and overall power handling depends on the
design of the specific device or the circuitry. The inverter does not produce any power. The
power is provided by the DC source.

ADVANTAGES OVER ROPE/BELT

a) No slip takes place during chain drive hence there is perfect velocity ratio.
b) Since the chain is made of metal, they occupy less space in width.
c) It gives high transmission efficiency.
d) Transmits more power than bolts
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4. Objective

• To produce a treadmill with Electricity Generator at low cost.

• To understand the construction and working of existing treadmill.
• To elaborate and discuss the modified design with respect to generation of electricity by using
mechanical energy.
• To design different mechanical components to receive maximum mechanical energy to
generate electricity.
• To provide a treadmill with Electricity Generator to reduce the pollution at some extent by
saving energy.
• Modify the design data with respect to material properties, cost analysis, performance analysis,
aesthetic and ergonomics as
well as future scope.
• Develop or manufacturing the modified treadmill as per requirement.
• To provide a treadmill with Electricity Generator. This is simple in design.
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4.1 Flowchart:-
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5 Material selection:-
a) ShaftMaterial :- Designation = C45,
Condition = Tubes, Cold drawn and tempered,
Yield Tensile Strength (Syt) = 600 N/mm2
Ultimate Tensile Strength (Sut) = 700 N/mm2

b) Bearing:-
Designation = 16006.
Bearing Material = Chrome Steel.

c) Bed Material:- Mild Steel.

d) Handle structure:- material = Aluminium

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4. Calculations:-
4.1 Design of shaft

Fig.3: Structure of shaft

1
Collecting
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Maximum allowable load = 150 kg = 1471.5 N

Length of Shaft= 600 mm
Uniform distributed load= 2.4525 N/mm
Consider simply supported load
Material:-
Designation = C45
Condition = Tubes, cold drawn and tempered
Yield tensile strength (syt) = 600 N/mm2
Ultimate tensile strength (Sut) = 700 N/mm2
Where,
Ƭp = Permissible shear stress,
Syt = Yield tensile strength.
Ƭp = 0.3 * Syt = 0.3 * 600
= 180 N/mm2
Where , Ƭp = Permissible shear stress,
Sut = Ultimate tensile strength.
Ƭp = 0.18 * Sut
Ƭp = 0.18 * 700
Select whichever smaller value , Ƭp = 126 N/mm2
Assume, kb=1.5 and kt=1
1.5 =
2𝜋T ∗ 1500
60 ∗ 106
T = 9549.29 N-mm.
Mmax = (2.4525*600)*300
Ƭp = 0.3 *Syt
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Ƭp = 0.18 *Sut
Ƭp = 126 N/mm2
P KW =
2𝜋NT
60 ∗ 106
Mmax = 441450 N-mm.
As per ASME code,
𝜋𝑑3 ∗ 126
16
= (1.5 ∗ 441450)2 + (1 ∗ 9549.29)2
𝜋𝑑3 ∗ 126
16
= 662243.852
𝑑3 = 26768.097
d = 29.91
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4.2 Bearing selection and design :-

Fig.3: Structure of Bearing

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 ∗ 9.81
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4
= 490.5 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 dyanamic load is given by,
P = V * Fr
= 1.2*490.5
Bearing life (L10) :-
We take L10h= 16000, From V.B.B table 15.2
L10 =
60n𝐿10ℎ
106
Where, n = Speed of rotation (rpm)
𝐿10ℎ = Rated bearing life (hours)
𝐿10 = Bearing life (mill.revln)
𝜋𝑑3Ƭp
16
= (𝑘𝑏 ∗ 𝑀)2 + (𝑘𝑡 ∗ 𝑇)2
d ≃ 30mm
P = 588.6 N.
60 ∗ 1500 ∗ 16000
106
Then, We find Dynamic load capacity (C)
C = P * (L10h)1/3
= 588.6 (1440
C = 4985.04 N
4.3 Belt selection and design:-
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Fig.3: Structure of Belt

P = 1.5 KW
Load correction factor = 1.2
Maximum power = 1.2*1.5 = 1.8 KW
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𝛼𝑠 = 180 −
2 sin−1(67 − 50)
2 ∗ 1520
𝛼𝑠 = 179.359
𝛼𝑠 ≃ 180 .
Hence, arc of contact factor, Fd = 1
= 1.8 * 1
= 1.8 KW
Power corrected = 1.8 KW.
Assume n = 120 rpm not 1500 rpm as human being run on the belt to measure velocity.
Belt velocity is given by,
v=
𝜋∗𝑑∗𝑛
60 ∗ 103
v=
𝜋∗𝑑∗𝑛
60 ∗ 103
v=
𝜋 ∗ 67 ∗ 130
60 ∗ 103
Corrected KW rating =
0.0118 ∗ 𝑣
5.08
Corrected KW rating =
0.0118 ∗ 0.4560
5.08
Corrected KW rating = 1.0593 ∗ 10−3KW.
width ∗ plies =
𝑐𝑜𝑟𝑟𝑒𝑐𝑡𝑒𝑑 𝑝𝑜𝑤𝑒𝑟
𝑐𝑜𝑟𝑟𝑒𝑐𝑡𝑒𝑑 𝑏𝑒𝑙𝑡 𝑟𝑎𝑡𝑖𝑛𝑔
width ∗ plies =
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1.8
1.0593 ∗ 10−3
width ∗ plies = 1699.23
For 4 plies,
width =
1699.23
4
width = 424.8 mm
width = 43 cm.
Width ≃ 43 cm.
Length of Belt is given by,
L = 2 ∗ 1260 +
(67 + 67)
2
+
(67 − 67)2
4 ∗ 1520
L = 2730.48 mm
Power corrected = (KW)max * Fd
v = 0.4560 m/s.
L = 2𝐶 +
𝜋(𝐷 + 𝑑)
2
+
(𝐷 − 𝑑)2
4𝐶
L = 273 cm.
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8. Future Scope :-
• Use of this treadmill in gym and fitness centers, by this we can generate electricity to lighten up
the premises.
• Use to charge the battery by this modify treadmill.
• Run LED bulbs and electrical instruments.
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9. Conclusion :-
• 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.
• Strength of muscles can be improved by using this manual treadmi
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References:-
[1] Harsh Mankodi, “Analysis of a Treadmill Based Human Power Electricity Generator”,
Submitted under the supervision of
Prof. Rusen Yang to the University Honors Program at the University of Minnesota-Twin Cities
in partial fulfillment 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).