Design and Fabrication of a Pedal-Driven Rope Twisting Machine with Integrated Power Generation

Power optimization and environmentally conscious methodologies have emerged as crucial elements in tackling contemporary issues concerning resource management, ecological preservation, and socio-economic advancement. The demonstrated initiative, entitled "Engineering and Construction of an Integrated Pedal-Driven Rope Twisting Manufacturing Device with Power Generation," represents an inventive strategy to concurrently tackle energy production and conventional rope fabrication requirements [5, 6]. Through utilizing human-operated systems and integrated designs, this apparatus combines a pedal-driven generator with a rope-twisting manufacturing device, establishing a multipurpose instrument for varied applications. The fundamental goal of this initiative involves engineering and constructing a system that employs pedaling mechanisms to twist coconut fiber or yarn into cordage while producing electricity [7, 8]. This integrated system functions in twin modes: one operated by human energy through pedaling. The initiative seeks to benefit communities and industries by delivering a sustainable, environmentally friendly, and economical solution that connects traditional craftsmanship with contemporary technological progress. Conventional rope fabrication methods, despite their cultural importance, frequently encounter constraints in productivity and expansion capability. Conversely, contemporary electric rope manufacturing systems demand steady power supplies, which remain unavailable in countryside or isolated locations. This initiative seeks to bridge this divide by providing a solution that merges the straightforwardness of conventional approaches with the dependability of modern power systems. Through this approach, it supports rural and small-scale manufacturing, particularly in areas where electricity remains unreliable or inaccessible. The suggested system provides considerable benefits by encouraging physical wellness, supplying a dependable electricity source, and enabling uninterrupted operation. In its primary mode, the system employs human pedaling to create mechanical energy, which transforms into rotational movement to operate the rope manufacturing mechanism [10, 11]. Concurrently, this mechanical energy converts into electrical energy using a generator or dynamo, which accumulates in a battery for subsequent utilization. This accumulated energy can operate DC devices directly or undergo conversion to AC using an inverter for operating more demanding equipment. The breakthrough in this initiative centers on its twin functionality and adaptability. Through combining rope manufacturing and power production into a unified system, the design optimizes component utility while reducing expenses. The pedal-operated mechanism encourages health and fitness by promoting physical exercise, establishing it as a practical instrument for fitness facilities and educational establishments. Simultaneously, its capability for off-grid energy production makes it perfect for rural communities, farming regions, and emergency relief areas where dependable energy sources prove essential [13, 14, 15]. This initiative also emphasizes the environmentally conscious characteristics of its operation. It generates no toxic emissions, depending entirely on mechanical and electrical components to perform its functions. Through promoting sustainable methodologies, it corresponds with worldwide initiatives to minimize carbon emissions and shift toward renewable energy sources. The creation of this system demanded thorough planning and incorporation of diverse mechanical, electrical, and electronic components. The pedal mechanism connects to a chain drive and gear assembly, which transmits rotational energy to the rope manufacturing roller. A generator linked to this mechanism captures the mechanical energy and transforms it into electricity. For enhanced efficiency, the system incorporates a boost converter and an inverter to regulate energy distribution and compatibility with different appliances.

LITERATURE REVIEW

Anoop Kumar et al. [23] Contemporary research addresses dual approaches to sustainable energy generation: human-powered mechanical systems and solar photovoltaic technologies. Studies demonstrate that pedal-powered generation serves rural electrification needs while solar energy advancement supports broader environmental sustainability goals through technological innovation and market expansion. Rahil patel et al. [24] Conventional pedal-powered grinding machines are limited in application, time-consuming, and less efficient. Recent developments focus on multipurpose designs that can perform grinding, pumping, washing, cutting, and even electricity generation. These systems not only improve efficiency and output but also provide health benefits through physical exercise. Kunal Kumar et al. [25] Electrical energy is vital for modern society and rural development. This research investigates a hybrid design through MATLAB simulation under load conditions. The study compares photovoltaic systems with low DC input voltage to pedal generation techniques. IGBT replaces MOSFET to improve converter efficiency under low power and input voltage conditions. Joya Shaikh et al. [27] Studies emphasize the need for alternative energy sources due to the depletion of fossil fuels and their environmental impact. Human-powered energy generation, particularly through stationary bicycles, has been explored as a simple and sustainable method. The mechanical energy from pedaling can be converted into electrical energy, stored in batteries, and used for basic utilities like lighting. Research suggests that utilizing human power can help bridge the energy gap, especially in areas with limited access to conventional electricity.

Proposed System Design and Working Principles    

The developed system integrates a dual-purpose pedal-driven rope fabrication device with an embedded electrical generation unit, utilizing combined mechanical and electrical components to achieve twin objectives: rope manufacturing and power production.

Figure 1: Block Diagram of Proposed System Design

The system initiates through human-powered pedaling, generating primary mechanical energy in torque form. This energy source can originate from manual pedaling by an operator or through substitute drive mechanisms such as brushless DC motors that replicate pedaling dynamics. This adaptable approach enables system customization according to diverse user requirements and operational conditions. The human-generated power transfers through integrated gear chains and flywheel belt systems. These gear assemblies serve essential functions in modifying rotational velocity and torque characteristics, enhancing power delivery efficiency to downstream components. The flywheel mechanism, functioning as a substantial rotating mass, operates as an energy stabilization device. It accumulates rotational energy during high-input intervals and distributes stored energy during low-input periods, eliminating power variations and maintaining steady energy distribution throughout the system. This essential subsystem transforms rotational movement into linear displacement through sophisticated pulley and cable arrangements. The motion conversion unit employs carefully engineered pulley configurations and rope systems to accomplish this mechanical transformation. The architectural design and component arrangement of this conversion mechanism directly determine the system's operational efficiency and force generation capacity. Several motion conversion units operate collectively to magnify the force output generated by individual rope mechanisms. This force multiplication proves vital for effectively powering subsequent system stages. The quantity of integrated conversion units can be modified to satisfy specific power demands and enhance overall system performance characteristics. The enhanced linear movement from the integrated rope systems operates a direct current generator. This generator transforms mechanical energy back into electrical form, subsequently storing the generated power in battery systems. The selection of DC generator technology, including permanent magnet or electromagnetically wound configurations, directly affects generator efficiency and electrical output properties. The boost converter optimizes electrical power flow and ensures effective battery charging processes. This DC-to-DC conversion device regulates voltage and current parameters, preventing battery overcharging while extending battery operational lifespan. For alternating current applications, the stored DC battery power undergoes conversion to AC power through inverter technology. The inverter's conversion efficiency and output waveform characteristics are fundamental for reliable AC device operation. The generated electrical energy supplies various electrical loads, including direct current devices (lighting systems) powered directly from battery storage, or alternating current equipment (lighting systems) operated through inverter conversion. This operational flexibility enables system adaptation across different applications and diverse power requirement scenarios.

HARDWARE SETUP

Figures illustrate the dual-functional design:

Layout-1 focuses on rope manufacturing through hybrid pedal and motor assistance.

Figure 2: Layout of dual-functional design

An integrated pedal-driven rope fabrication system combines human energy input with mechanical elements including gear assemblies, chain drives, and rotating cylinders to transform fibers into durable and consistent rope products. The configuration enables operators to power the twisting apparatus through manual effort or employ electric motor support for improved speed and output capacity when necessary. Gear and pulley arrangements transform mechanical energy into spinning motion, guaranteeing effective twisting of multiple fiber strands. Quality assurance is maintained through tension regulation systems that prevent loosening or excessive twisting, while completed rope products are automatically coiled and sectioned to specified dimensions. This power-efficient combined system decreases operator fatigue, reduces electrical consumption, and enhances production rates, making it suitable for environmentally conscious small-scale manufacturing operations.

Layout-2 demonstrates power generation via pedaling and DC generator integration.

Figure 3: Power generation via pedaling and DC generator integration

Likewise, an additional project concentrates on capturing human pedaling energy to produce electricity via a direct current generator, establishing a semi-autonomous power generation system. The pedaling action transforms kinetic energy into low-voltage direct current, which is regulated to 24V through a DC-DC step-up converter and accumulated in a battery array consisting of two 12V, 7Ah lead-acid cells connected in series. This accumulated power operates a DC-AC converter to deliver 220V alternating current for devices such as a 9W LED lamp.

MATERIAL AND METHOD                                  

Pedal driven rope twisting machine is dual-purpose apparatus integrates multiple interconnected elements to transform manual pedaling motion into simultaneous rope manufacturing and electricity production. The fiber processing unit mechanically creates rope through automated spinning techniques encompassing twisted, braided, and woven configurations, with mechanical force transmitted via chain-driven mechanisms from the pedaling assembly to the rope fabrication modules and guide wheels. A one-way gear mechanism facilitates precise rotational force distribution while eliminating reverse rotation during pedaling cycles, maintaining consistent operational flow. The human-generated kinetic energy powers a 24-volt direct current dynamo that transforms rotational movement into electrical current via electromagnetic conversion, storing energy within a dual 12-volt, 7-ampere-hour lead-acid battery configuration arranged in series to establish a dependable 24-volt power supply. Electronic control systems feature an XL6009 step-up voltage regulator that manages power flow for optimal battery charging with built-in safety mechanisms, alongside a power inverter that transforms 24V direct current into 220V alternating current suitable for operating conventional devices such as LED lighting. The structural framework incorporates heavy-duty pedaling cranks constructed from aluminum alloy or steel materials for maximum energy transfer efficiency, a rotational stabilizer manufactured from cast iron or steel that regulates spinning momentum and ensures uniform power distribution, plus a sturdy carbon steel chassis that furnishes structural integrity while functioning as the primary mounting platform for all system elements, guaranteeing operational stability throughout use.

Hardware Specifications

Table 5.1 Overall Specifications of Selected Materials

Pedal Power Calculation:

For reference,

Crank teeth – 29 Nos.

Freewheel teeth – 17 Nos.

Rated Spindle – 60 rpm

Small Sprocket - Teeth 17 - Pitch Diameter 69

Large Sprocket - Teeth 29 - Pitch Diameter 117

Chain Links 60 - Chain Length 762

Sprocket Centres 234

Gear Ratio 1.706: 1

Chain Speed @ 60 RPM Small Sprocket 13 m / min

Motor Power Calculation

For reference,

Output mechanical power of the motor could be calculated by using the following formula:

P_out = T× ω

where

P_out – Output power, measured in watts (W);

T – Torque, measured in Newton meters (Nm);

ω – Angular speed, measured in radians per second (rad/s).

ω = Rpm × 2π / 60

where

ω – Angular speed, measured in radians per second (rad/s);

rpm – Rotational speed in revolutions per minute;

π – Mathematical constant pi (3.14).

60 – Number of seconds in a minute.

RESULTS AND DISCUSSION

 Output in Pedal Mode

Rated Spindle – 60 rpm

Gear ratio: 1.706:1 (large sprocket to small sprocket)

The output speed (generator speed) is calculated as

Output RPM = Input RPM * Gear ratio

Eg:  Output RPM= 30*1.706 = 51.18

DAY 1: Low speed

Table 6.1.1 Power generation in day 1

Fig. 6.1.1 DAY 1: Output Voltage Vs Low Speed

DAY 2: Moderate speed

Table 6.1.2 Power generation in day 2

Fig. 6.1.2 DAY 2: Output Voltage Vs Moderate Speed

DAY 3: Intermediate speed

Table 6.1.3 Power generation in day 3

Fig. 6.1.3 DAY 3: Output Voltage Vs Intermediate Speed

DAY 4: High Speed

Table 6.1.4 Power generation in day 4

Fig. 6.1.4 DAY 4: Output Voltage Vs High Speed