DEVELOPMENT AND FABRICATION OF

ELECTROMAGNETIC ENGINE

Submitted by
Avin Ganapathi
Rithin R
Srinivas Rangan L
Vinay M

A PROJECT WORK
PROPOSAL ON

DEVELO
PMENT

Submitted By
AVIN
Under the Guidance of
GANAPATHI(4MH09ME010)
Prof. B HARISH
Assistant Professor
RITHIN R(4MH11ME094)
Department of Mechanical
SREENIVAS RANGAN
Engineering
L(4MH11ME104)
MIT Mysore
VINAY M(4MH11ME118)
DEPARTMENT OF MECHANICAL ENGINEERING
MAHARAJA INSTITUTE OF TECHNOLOGY
MYSORE - 571438

Index
1. Introduction
2. Literature survey
3. Overview
4. Components and description
5. Design Calculations
6. Fabrication and Assembly
7. Cost estimation
8. Testing

9. Result
10. Conclusion and Scope for future
development
References.
Fabricated model photographs

Introduction
Conventional Engine Concept
An Internal Combustion is an engine where
combustion of fuel occurs with an oxidizer in
combustion chamber that is an integral part of
working fluid flow circuit.

Drawbacks of IC engine
Air pollution.
Because of high demand and decreasing
supply, the price of fuel is increasing.
Running cost Maintenance cost is high.
Manufacturing cost is high.

Windings on core
The force that sets up the magnetic field depends on the
number of turns on the coil and the magnitude of the current flowing.
This force is called the Magneto Motive Force and is measured in
Ampere-turn.

MMF=I*n Amp-turn

Current carrying conductor

Literature survey

OVERVIEW
Objective
To Develop and fabricate an Electromagnetic
engine
Testing of Engine for its power output and
efficiency
To Evaluate the Performance of Electromagnetic
Engine

Methodology

COMPONENTS AND DESCRIPTION

Cylinder

 Piston

 Connecting rod

 Flywheel

 Electromagnet

Diameter

0.065 m

Height

0.080 m

An electromagnetic coil is formed when an insulated solid

copper wire is wound around a core or form to create an inductor
or electromagnet. When electricity is passed through a coil, it
generates a magnetic field. One loop of wire is usually referred to
as a turn or a winding. we have wound 350 turns.

RELAY
A relay is an electrically operated switch.
Current flowing through the coil of the relay creates
a magnetic field which attracts a lever and changes
the switch contacts.

 Battery

The batteries we are using is lead acid battery which

has a nominal supply voltage 12 volts and 7Ah
current. By series combination we get supply voltage
of 36 volts.

TIMER 555 IC

TIMER 555 IC is used to control accurate time delays

for Relays to switch ON and OFF.

DESIGN CALCULATION
Input voltage = 36 V
Input current = 10A
Input Power = Voltage Current= 36 10 = 360W
Force exerted by electromagnet on piston:
F1=

22

Where, N = number of turns = 350

I = Current flowing through coil = 10 A
K = Permeability of free space = 410-7
A = Cross-sectional area of electromagnet (radius
r = 0.0325m)
G = Least distance between electromagnet and
permanent magnet = 0.01m
d = diameter of electromagnet = 0.065 m
On substitution we get
Max Force F1 = 255.40 N

Force exerted by permanent magnet:

F2 =
B=
On substituting the value of flux density we get
F2 = 11.1 N
F = F1 + F2
= 266.48N

Torque
T = F r
Where F = total force on piston = 266.50 N
r = crank radius = 0.01m
T = 266.50 0.01
Torque T = 2.665 N-m

25

Mass of Flywheel
Energy stored on Flywheel
E=T
Where T= torque
0
= Angle of rotation = 180
0
on substitution we get
E = 6.372 Joules
Also,
E= 0.5I2
I = 0.0189 kg-m2

radians

I= 0.5 m r2
Where , m = mass of fly wheel
r = radius of fly wheel = 0.085 m
m = 2.12 kg.
Output Power:
Where,
N = speed= 200rpm
T = Torque= 2.665 N-m
On substitution,we get
P = 55.71 W

EFFICIENCY
Efficiency = =
= 15.51 %

Factor of Safety of Cast Iron Frame

Working stress,

F =29.9 N/mm2

Where L = Length of the frame in mm,

W = Weight acting on the frame in Kg
b = Breadth in mm
d = Depth in mm
Factor of Safety, FOS =

=
FOS = 4.3
When Factor of Safety is greater than or equal to 1,
then the Design is safe.
i.e.,
FOS 1
4.3 > 1, hence Design is Safe.

FABRICATION AND ASSEMBLY

CYLINDER
width

0.075 m

length

0.075 m

height

0.1 m

Bore diameter

0.038 m

The cylinder developed is made of aluminum, a nonmagnetic material which limits the magnetic field
within the boundaries of cylinder periphery. Usage of
aluminum material makes the engine lighter unlike the
cast-iron cylinder used in internal combustion engine.

31

PISTON
Diameter

0.038 m

height

0.034m

The hollow piston casing is made up of non-magnetic

stainless steel.
One end of the hollow case is fitted with a powerful
permanent magnet made of neodymiumiron-boron
(NdFeB)

32

CONNECTING ROD

Length

0.086m

Big end diameter

0.012m

In a reciprocating engine, the connecting rod is used to

end diameter
0.010m
connect the piston to theSmall
flywheel.
It converts
the linear
motion or reciprocating motion of the piston to the
circular motion of the flywheel. The material of the
connecting rod is cast iron. The connecting rod used is
same as that of an Internal Combustion engine without
any modification

33

FLYWHEEL

Flywheel is made up of mild steel and it is used to convert

reciprocating energy into rotational energy. It regulates the
engines rotation, making it operate at a steady speed . The
diameter of the outer circle is 170mm and of the through hole at
the center is 30mm

34

ELECTROMAGNET

Diameter

0.065 m

An electromagneticHeight
coil is formed0.080
when
an
m
insulated solid copper wire is wound around a core or
form to create an electromagnet. When electricity is
passed through a coil, it generates a magnetic field. One
loop of wire is usually referred to as a turn or a winding.
we have wound 350 turns.

35

SUPPORT FRAME

The support frame is made up of cast iron. It

m
holds the piston and cylinder Length
assembly 0.61
with
0.26 m
electromagnetic coil arrangement. TheWidth
length, breadth
Height260mm
0.28and
m
and height of the stand are 600 mm.
280mm respectively. The manufacturing process
involved are cutting and welding

36

ASSEMBLY
The setup is as follows:
The electromagnetic coil is held
between two fixed supports on the
frame.
Similarly the cylinder block is mounted
on the fixed electromagnetic coil
NdFeB permanent magnet is attached
to the piston head by means of a strong
adhesive.
Piston is mounted inside the cylinder.
The small end diameter of the
connecting rod is fixed to a piston and
the big end diameter to the flywheel.
And the flywheel converts
reciprocatory motion of piston into
rotary motion.

COST ESTIMATION
Sl. No.

Name of
the Parts

Material
Used

Qty.

Amount
(Rs)

Battery

2100

Permanent
magnet

Neo
Dymium
Boron

1000

Stand
(Frame)

Cast iron

1000

Electromagn et

2000

Relay and Ic
timer

500

Piston

Stainless
steel

1500

Connecting
rod

Cast iron

600

Flywheel

Mild steel

900

Nut and

Mild steel

20

 Material Cost =Piston+ connecting rod +

flywheel + Nuts and Bolts
= 1500 + 600 + 900+20
= Rs. 3020/ Fabrication Cost =Rs. 2000/ Total cost = Component cost + Material
cost + Fabrication cost = Rs.11620/ -

TESTING
Variation of Current with Force
Current, amp

Force, N

21.48

52.07

103.07

174.47

10

266.27

Variation of input Power with Efficiency

Power input

Efficiency

72

6.09

144

7.56

216

9.98

288

12.68

360

15.48

RESULT
The prototype of an electromagnetic engine which works on
the principle of magnetism was successfully developed, fabricated and
tested. Result analysis was done on the prototype. The results
obtained are as follows.
Prototype of an engine which works on the principle of magnetism
was tested successfully.
It uses electricity as its input without fuel.
The prototype creates no pollution and is eco-friendly.
Only the repulsive force between the magnet and electromagnet is
used for power generation.
Acceleration is done by controlling the timer which controls the relay.
Maximum efficiency obtained was 15.81 %.
Maximum output power obtained was 55.81 W .

CONCLUSION AND SCOPE FOR FUTURE

DEVELOPMENT
The prototype is an idea which uses the property of an
electromagnet by virtue of which it changes the polarity of its poles whenever
the direction of current is changed. This variation in polarity is utilized to attract
or repel the permanent magnet attached to the piston. The usage of relay and
timer will limit the output of the engine. By using an ECU in the engine instead,
power can be obtained on each stroke which will result in an increased output.
Also, by inserting more permanent magnets in series on the piston will enhance
the output of the engine. By slight modification in design and by the use of
better hands the engine can be modified to generate more power, thereby
increasing its efficiency, so that it can be used in commercial vehicles and other
applications.

Jeff BairdA inventor whose creation was recently featured in Popular

Science magazine unveiled his latest invention Saturday.
Ada area resident Jeff Bairds newest invention is an
engine that uses a technology that really isnt new at all.
Large batteries fire the magnets and the motor acts as an
alternator that keeps the batteries charged continuously.
The technology works like windmills except it uses magnets
instead of wind.

Peter van Blarigan-

References

[1]Atulkumarsingh, PrabhatRanjanTripathi, Microcontrolled Electromagnetic Engine, 2011, International

Conference on Advances in Electrical and Electronics Engineering (ICAEE'2011)

[2]J.Rithula,J.Jeyashruthi and Y Anandhi,Electric Vehicle with Zero-fuel ElectromagneticAutomobile

Engine,2013,1,2&3Department of Electrical & Electronics Engineering, Sri Sairam Engineering College, West
Tambaram, Chennai, India. Volume 6, Number 4 (2013), pp. 483-486

[3]Shirsendu Das,An ELECTROMAGNETIC MECHANISM WHICH WORKS LIKE AN ENGINE, IJETT- Volume 4
Issue 6-June 2013

[4]Abil Joseph Eapen, AbyEshowVarughese, Arun T.P,Athul T.N, 2014,

ELECTROMAGNETIC ENGINE, International Journal of Research in Engineering and Technology.

[5]AmarnathJayaprakash, Balaji, G., Bala Subramanian, S. and Naveen, N.,STUDIES ON ELECTROMAGNETIC

ENGINE International Journal of Development Research Vol. 4, Issue, 3, pp. 519-524, March, 2014

[6]C. Sudhakar, K. Premkumar, K.Vijith, S.Balaji,EMISSIONLESS ENGINE BY USING ELECTRO MAGNET,

2014
[7]K.Mahadevan and L.Balaveera Reddy DESIGN DATA HAND BOOK for Mechanical Engineers, Third Edition.

[8]Peter van Blarigan, ADVANCED INTERNAL COMBUSTION ENGINE RESEARCH Proceedings of the 2000
DOE Hydrogen Program Review.

Fabricated model photographs

Cylinder

Piston with Connecting rod

Flywheel

Electromagnet

Relay and timer

Battery

Assembly