1

CHAPTER 1
INTRODUCTION

In today’s fast moving world energy demands & use is even

increasing. Energy has always been an issue for sustainability. The coal
reserve, which the main fissile fuel to generate electrical power, is
estimated to last only for about 200 year more. In regarding this problem,
all sorts of sustainable energy sources like solar, wind & hydropower
emerge.

We would like to investigate an alternative energy source: human

power. To cope up with these even increasing energy demands our need
to derive various mechanisms those are capable to generate electricity.
We would like to convert kinetic energy of people walking stairs into
electricity.

The Staircase electricity generator is specially planned to design

and fabricate the conversion unit for utilizing the available unconventional
energy source. That is tremendously available energy in low intensity with
ample quantity can be utilized.

Staircase electricity generation as such is not a new concept. There

were many attempts in the past using pneumatics, piezoelectric materials
etc. but all of them proved very costly and were not practically feasible in
day-to-day real life.

Actually whenever people walk on stairs, they loss their energy, we

have design such a mechanism in which we have used this waste energy
to generate electricity. One of motive of the project is to implement this
mechanism in a scaled down model and then check the feasibility of such
mechanism and the results towards making one more economical. The
project model is constructed from MDF sheet & various subcomponents

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like bearings, D.C. Generator, springs, chain, Flywheel, PVC Pipe and
Freewheel.

PICTURE: - 1.1 Model of Staircase Electricity Generator

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CHAPTER 2
LITERATURE

In this fast moving world, we are totally dependent upon

conventional energy sources. But these sources are assumed to last for
about 200 years. Staircase electricity generation as such is not a new
concept. There were many attempts in the past using pneumatics,
piezoelectric materials, etc. but all of them proved very costly and were
not practically feasible in day-to-day real life .The persons, which are
climbing or getting down the staircase are applying the impact force or
thrust on the spring loaded stair case steps. This impact pressure energy
can be utilized to operate the energy flywheel through uni-directional
ratchet arrangement using chain and sprocket wheel drive. The flywheel
stores the energy and utilizes for continuous rotation of the generator
operating pulley and belt transmission system. But it was too expensive,
time consuming and complex to implement.

We have tried to generate electricity besides these sources by

using human efforts by using simple mechanical means like chain,
freewheel, pulley, wire rope etc, which are simple in design and can be
easily implemented. And which reduce its cost.

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CHAPTER 3

CONSTRUCTION
3.1 THEORY

This project model is built using MDF (medium density fiberboard)

sheets as main constituent having 12mm, 8mm & 6mm thickness for
different component, ½” PVC plumbing pipe, nylon threads, studs, bearing
6000 zz, chain, elastic rubber, nuts &bolts, d.c generator, rubber bush &
L.E.D (light emitting diode ).

The steps are 6 in no. & 30cm x 12cm in size crafted out of 6mm
thickness MDF sheets. Which are supported from Underneath with
support bans crafted out of 8mm MDF sheets & approx.19mm long with a
pivot joint situated at 17cm. These steps are pivoted to main frame at fix
element of 12 cm with the help of screws. The main frame is constructed
with 12mm MDF sheets & in 63cm long &7 cm wide. These are two
sheets of above mentioned size placed at a distance of 19 cm with the
help of studs .The two support that holds steps are held with the main
frame, one of the supports extends to 7cm at an angle 45˚. This extended
support is fitted across motion limitation that allows the steps swivel
through 20˚ only .The extended support is held to become to the main
frame using elastic limits.

Odd & even numbered steps are connected for forcing two set of
steps, with the help of nylon strings. The nylon string runs over a pulley
situated at the lower end of main frame. The main frame is made to a
slant of 45˚using a support frame crafted out of 12 mm MDF sheet of size
55mm x 5mm fitted at other end of main frame. The strings running over
the pulley are connected directly with the chain that is connected with the
main frame using flexible tensile. This chain runs over freewheel. These
strings freewheel & chain arrangement is done in two numbers for two

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sets of steps. These two freewheels are mounted on the PVC pipe which
in connected to bearings at each ends. These bearings are mounted with
a sub frame to the mainframe. At one end of PVC pipe a 24mm thick &18
cm dia. flywheel is connected made out of MDF sheets.
On this flywheel is supported with d.c generator with a floating
truck. The generator rubber bush on the shaft which messes physically
with the periphery of the fly wheel the d.c generator is connected with
L.E.D to show electricity generation.

FIGURE: - 3.1.1 Pulley Holder

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FIGURE: - 3.1.2 Side Frame

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FIGURE: - 3.1.3 Bearing Bracket

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FIGURE: - 3.1.4 Bearing Bracket Holder

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FIGURE: - 3.1.5 Stair Gripper

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FIGURE: - 3.1.6 Main Frame

FIGURE: - 3.1.7 Stair Support

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FIGURE: - 3.1.8 Pulley

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FIGURE: - 3.1.9 Stair

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FIGURE: - 3.1.10 D.C. Generator Bracket

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FIGURE: - 3.1.11 Flywheel

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3.1.1 BODY

3.1.1.1 Medium density fiberboard (M.D.F. sheet)

It is an engineered wood product formed by breaking down

hardwood or softwood residuals into wood fibers, often in a deliberator,
combining it with wax and a resin binder, and forming panels by applying
high temperature and pressure. MDF is denser than plywood.
It is made up of separated fibers, (not wood veneers) but can be
used as a building material similar in application to plywood. It is much
denser than normal board. The name derives from the distinction in
densities of fiberboard. Large-scale production of MDF began in the
1980s.
It is an excellent substrate for veneers. It is becoming an
environmentally friendly product. Some varieties are less expensive than
many natural woods. Isotropic (its properties are the same in all directions
as a result of no grain), so no tendency to split. It is Consistent in strength
and size. it can be used for curved walls or surfaces. MDF is often used in
school projects because of its flexibility. It is also often used in
loudspeaker enclosures, due to its increased weight and rigidity over
normal plywood. Slat wall Panels made from MDF are used in the fitting
industry.

3.1.1.2 Nut & Bolt

Material: Mild Steel

Nut is used for tightening the various parts of staircase. There are
16 nuts used in this staircase. They are used to tight the Studs which are
located at the side frame & main frame. Also many nut & bolts are used to
join the stair with the side frame. Bolts also serve the purpose of stopper
for stair to maintain specific angle.

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3.1.1.3 Studs

PICTURE: - 3.1.1.3 Stud

It is a type of bolt which is threaded at both ends used for proper

alignment of main frame of staircase.

3.1.2 D.C. GENRATOR

It is based on the principle of production of dynamically (or

motional) induced e.m.f (Electromotive Force). Whenever a conductor
cuts magnetic flux, dynamically induced e.m.f. is produced in it according
to Faraday's Laws of Electromagnetic Induction . This e.m.f. causes a
current to flow if the conductor circuit is closed.

The basic essential parts of an electric generator are:

A magnetic field and A conductor or conductors which

can so move as to cut the flux.

PICTURE: - 3.1.2.1 D.C. Generator

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A single-turn rectangular copper coil abcd is moving about its own

axis in a magnetic field provided by either permanent magnets or
electromagnets. The two ends of the coil are joined to two split-
rings which are insulated from each other and from the central shaft. Two
collecting brushes (of carbon or copper) press against the split rings.

PICTURE: - 3.1.2.2 Function of D.C. Generator

3.1.3 BEARING (6000zz)

6000ZZ Inner Diameter= 10mm = 0.3937"

6000ZZ Outer Diameter= 26mm = 1.0236"
6000ZZ Width= 8mm = 0.3150"

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PICTURE: - 3.1.3 Bearing 6000zz

ZZ bearing all about, Bearing with ZZ letters in their item number

has metal shields inserted to the outer ring of the bearing, they are mainly
made to seal the bearing, sealed ZZ bearings has closures to protect the
bearing from dirt, dust or any possible contamination, sealed ZZ bearing
are lubricated with grease, you can always remove the closures,
relubricate the sealed ZZ Bearing with grease, re-inserting the metal
shields are not an easy job, they are usually bent when removed. Sealed
ZZ bearing has item number ends with ZZ which stands for 2 metal
shielded enclosures.

3.1.4 FREEWHEEL

The simplest freewheel device consists of two saw-toothed, spring-

loaded discs pressing against each other with the toothed sides together,
somewhat like a ratchet. Rotating in one direction, the saw teeth of the
drive disc lock with the teeth of the driven disc, making it rotate at the
same speed. If the drive disc slows down or stops rotating, the teeth of
the driven disc slip over the drive disc teeth and continue rotating,
producing a characteristic clicking sound proportionate to the speed
difference of the driven gear relative to that of the (slower) driving gear.

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PICTURE: - 3.1.4 Freewheel

A more sophisticated and rugged design has spring-loaded steel

rollers inside a driven cylinder. Rotating in one direction, the rollers lock
with the cylinder making it rotate in unison. Rotating slower, or in the
other direction, the steel rollers just slip inside the cylinder.

3.1.5 FLYWHEEL

The flywheel is a mass, usually a metal weight, fitted to a rotating

power transmission shaft or directly to the motor spindle. When power is
fed to the motor it will not react as quickly as the same motor without a
flywheel fitted, providing slower acceleration up to the voltage/speed
required. This is due to the motor having to work a little harder to start the
extra weight of the flywheel moving and get it spinning. Once the flywheel
is spinning at the desired speed it has an amount of stored kinetic energy
in proportion to the speed and weight of the flywheel. The kinetic energy
stored in the flywheel during running will resist `stuttering' rapid changes
in speed normally caused by small spots of dirt on the track or wheels
used for traction current collection. When the voltage to the motor is
reduced (or removed completely) the stored kinetic energy in the flywheel
will try to keep the motor spinning producing a smoother more gradual

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braking curve. (most small DC motors have very low mass/weight and will
stop very rapidly when the power feed is removed) The flywheel gives the
model more momentum resulting in more prototypical behavior and a
different `driving experience'. It does not take long to learn the
acceleration and braking characteristics of a model with flywheel(s) fitted
and once mastered they are much easier to drive in a prototypical manner
than models without flywheel(s).

Flywheel is a heavy wheel attached to the shaft of an engine to

keep its speed nearly constant. It is used where the forces driving the
engine shaft are not constant. Then the flywheel absorbs the excess
energy and prevents the speed from increasing rapidly. Then the
flywheel's inertia keeps the speed from decreasing quickly.

3.1.6 CHAIN

PICTURE: - 3.1.6 Chain

 Bicycle chain, chain that transfers power from the pedals to the
drive-wheel of a bicycle thus propelling it
 A chain is a series of connected links. This article is about the
literal, physical chain. A chain may consist of two or more links.
 A chain is usually made of metal.
 Those designed for transferring power in machines have links
designed to mesh with the teeth of the sprockets of the machine,
and are flexible in only one dimension. They are known as Roller
chains, though there are also non-roller chains such as block chain

3.1.7 PVC PIPE

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Polyvinyl chloride commonly abbreviated PVC, is a

thermoplastic polymer. It is a vinyl polymer constructed of
repeating vinyl groups (ethenyls) having one of their hydrogen’s
replaced with a chloride group. Polyvinyl chloride is the third most
widely produced plastic, after polyethylene and polypropylene.
PVC is widely used in construction because it is cheap, durable,
and easy to assemble. PVC production is expected to exceed 40
million tons by 2016 .It can be made softer and more flexible by
the addition of plasticizers, the most widely used being
phthalates. In this form, it is used in clothing and upholstery, and
to make flexible hoses and tubing, flooring, to roofing
membranes, and electrical cable insulation. It is also commonly
used in figurines and in inflatable products such as waterbeds,
pool toys, and inflatable structures.

3.1.8 ACCESSORIES
3.1.8.1 NYLON THREAD

PICTURE: - 3.1.8.1 Nylon Thread

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Nylon thread is a light-weight nylon fabric with inter-woven

reinforcement threads in a crosshatch pattern. The material comes in
many different colors and sizes, including thickness. It is woven with
coarse, strong warp and filling yarns spaced at intervals so that tears will
not spread. It is use for power transmission from step of stairs to chain.

3.1.8.2 SPRING

PICTURE: - 3.1.8.2 Helical or coil springs

Material: Mild Steel Cr- V Steel,

Spring is held in between Ram and Ram cylinder. It is a square

cross section helical coil which having the main function is to resist the
force applied on the ram plunger & regained it original position after oil
returns in the pumping unit.

Hooke's law of elasticity states that the extension of an elastic rod

(its distended length minus its relaxed length) is linearly proportional to its
tension, the force used to stretch it. Similarly, the contraction (negative
extension) is proportional to the compression (negative tension).

This law actually holds only approximately, and only when the
deformation (extension or contraction) is small compared to the rod's
overall length. For deformations beyond the elastic limit, atomic bonds get
broken or rearranged, and a spring may snap, buckle, or permanently

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deform. Many materials have no clearly defined elastic limit, and Hooke's
law cannot be meaningfully applied to these materials.

3.1.8.3 ELASTIC RUBBER

Rubber bands are made by extruding the rubber into a long tube to
provide its general shape, putting the tubes on mandrels and curing the
rubber with heat, and then slicing it across the width of the tube into little
bands. While other rubber products may use synthetic rubber, rubber
bands are primarily manufactured using natural rubber because of its
superior elasticity. It is used for regaining the position of chain on
freewheels

3.1.8.4 RUBBER BUSH

PICTURE: - 3.1.8.4 Rubber Bush

It is used for making the proper contact with the flywheel. It is fixed
in the shaft of the D.C. Generator.

3.1.8.5 LED

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PICTURE: - 3.1.8.5 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. The LED is based on the semiconductor diode. When a diode
is forward biased (switched on), electrons are able to recombine with
holes within the device, releasing energy in the form of photons. This
effect is called electroluminescence and the color of the light
(corresponding to the energy of the photon) is determined by the energy
gap of the semiconductor. An LED is usually small in area (less than
1 mm2), and integrated optical components are used to shape its radiation
pattern and assist in reflection.

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CHAPTER 4
WORKING

It consists of six steps, as the steps of stair case unit. All the steps
are coupled to the big size sprocket wheel, which in turn is coupled to the
small sprocket wheel through the chain drive. The small sprocket wheel in
turn is coupled to the ratchet wheel, which allows only the uni-directional
rotation of the ratchet sleeve shaft. Similarly all the remaining two big
sprocket wheels are coupled to the same single shaft through the
separate chain drive individually.

Whenever weight is put on steps the steps get turned thereby

stretching the thread they are connected with which pulls the chain .The

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chain rotates the freewheel thus the freewheel rotate the fly wheel thus
the linear motion of step is converted into rotary motion of flywheel which
run the generator thus running the generation converted this mechanical
energy into electrical one.

When any person is stepping on the individual step, then that

particular sprocket wheel pair rotates the ratchet wheel and thus the main
shaft rotates at that instant. Thus the summation of the total rotational
energy accumulation takes place in a single main shaft. The single main
shaft is installed with the flywheel, which keeps on rotating with high
velocity. The flywheel using the belt drive being coupled with the
generator pulley rotates the generator field rotor and the EMF is
generated in the stator winding. The bulb coupled to the stator winding
glows up as a indication of the generation of the Un-conventional energy.

PICTURE: - 4.1 Working Model of Staircase Electricity Generator

Such type of multiple chain and sprocket drive is installed on the

each and every individual step to couple that particular step with the

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common shaft. The common shaft is installed with the freewheel which is
also called as unidirectional ratchet, which allows only unidirectional
motion of the chain drive when the person is stepping on the step. While
retaining of the step the ratchet will rotate as a free wheel. The
summation of all the rotational energy will keep on adding to have
collective rotation of the main or common shaft. The main shaft is coupled
with the flywheel with the help of a round cross sectional leather belt. The
flywheel stores energy during stepping condition and keeps on uniform
rotation. The flywheel shaft is coupled with the generator to generate the
power. This power can be stored in the lead acid battery set and can be
reutilized for other domestic as well as commercial purposes as per the
need of the customer.

One such attempt is made in this project work which in staircase

electricity generation system, when human using this staircase for
common floors electricity is developed.

CHAPTER 5
FABRICATION

5.1 JIG SAW CUTTING

This versatile power tool is the grand master of cutting shapes—in

lumber, plywood, sheet metal, even tile A jigsaw (also called a saber saw)
cuts in a rapid up-and-down motion. The key to excellent results with a
jigsaw is to match a specific blade to the type of material you’ll cut: wood,
metal, plastics, tile, etc. The blade package will indicate what material the
blade cuts best.

Most blades are carbon steel, 2 to 3-1/2 in. long and either 1/4 in.
wide for making tight radius cuts or 3/8 in. wide for general-purpose
cutting. Orbital cutting action. If you’ve ever rocked a handsaw up and
down while cutting a board or firewood, you’ve noticed how this speeds

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the cutting action. Jigsaws with this feature have dialed settings that
change the pitch of the blade from straight up and down for metal cutting
to angle forward for aggressively cutting wood.

Longer blade stroke. Using a jigsaw that delivers a 1-in. long blade
stroke will get you through a job faster than using a saw with a 1/2-in.
long stroke. Blade guides. Saws so equipped have a pair of rollers or
other guides below the blade clamping assembly to steady the blade for
less bending and greater accuracy.

A jigsaw with preset speed settings or a variable speed trigger

allows you to customize each cut and to slow down when you’re at a
tricky point in a pattern. This helps you work with a wide variety of
materials and densities, too Orbital cutting action. If you’ve ever rocked a
handsaw up and down while cutting a board or firewood, you’ve noticed
how this speeds the cutting action. Jigsaws with this feature have dialed
settings that change the pitch of the blade from straight up and down for
metal cutting to angled forward for aggressively cutting wood.

5.2 DRILLING

The main function of drilling machine is to originate a hole, it

can perform the number of similar operations. In a drill machine holes
may be drilled quickly and at a low cost. The hole is generated by the
rotating edge of a cutting tool known as the drill which exerts large force
on the work clamped on the table. As the machine exerts vertical pressure
to originate a hole it is loosely called a “drill press”.

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CHAPTER 6
COSTING OF MODEL

6.1 COST

Cost may be defined as the amount of expenditure incurred on, or

attributable to, a given thing.

6.1.1 COSTING EVALUATION

A process design is not complete until one good idea of the cost
required to manufacturing the product generally the cost (lowest) design
will be successful in free market place. So on understanding of the
element that makeup cost is vital.

6.1.2 ELEMENT OF COST

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The constitutions a cost of a product or a cost element can broadly

be in (1) Recurring cost or manufacturing cost or operating cost and (2)
Non recurring cost. They may design again be classified as direct cost
and capital cost recurring cost inside include an indirect cost, while capital
cost come under non recurring cost.

6.1.3 DIRECT COST

They are the cost of those factors which can be directly attributed
to the manufacturing of a specific product. These include cost of material,
power and labour.

Material cost associated with that material which goes in to finished

product and include all waste which has been scraped away from the
original stock. Labour cost varies from machine to machine and usually
calculated by multiplying the time require for an operation by a labour
rate. Thus, the time to setup and perform and operation must be set up
perform and estimated to find out its labour cost.

6.1.4 CAPITAL COST

This are one time cost or Non recurring cost which include
depreciable facilities such as plant building or manufacturing equipment
tool and non depreciated capital cost. Such as land, capital cost is
determined by distributing the major machine and tool cost any hourly
basis or among the plate piece produced.
The total cost of a product is the direct cost of manufacturing the
production and any direct cost associated with the manufacturing the
product in order to process engineer to use cost data as a tool to help in
analysis manufacturing problem cost any be more convenient grouped as
fixed cost and variable cost.

6.1.5 FIXED COST

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This include initial cost such as cost of tooling, setting of etc. and
also the interest and depreciation cost which are independent of the
quantity of the product manufactured.

6.1.6 VARIABLE COST

Variable cost are those cost which are varying as the quantity of
product manufactured carries this includes the direct labour, power,
material and also that part of the direct cost which will vary as well as
production varies. The total cost of a product can also equal to the
summation of the fixed and variable cost.

6.1.7 OVERHEADS

Overheads are all expenses other than direct expenses. It is define

as the cost of indirect material, indirect labour and such other indirect
expenses, including, services, as cannot conveniently be charged direct
to the specific cost units.

6.2 COST STUCTURE

The elements of the cost can be combined with following types of cost:
PRIME COST
Direct material + Direct labour + Direct expenses = Prime cost
FACTORY COST
Prime cost + Factory expenses = Factory cost
MANUFACTURING COST
Factory cost + Administrative expenses = Manufacturing
cost
TOTAL COST
Manufacturing cost + Selling and Distribution cost = Total cost

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SELLING PRICE
Total cost + Profit = Selling Price

Table 6.2.1 COST TABLE

SR QUANTI
MATERIAL RATE TOTAL
NO. TY
1. MDF Sheet
(2,4,8,10mm) 1 4460.00 4460.00
2. Bearing 2 240.00 480.00
3. Freewheel 2 45.00 90.00
4. Chain 1 50.00 50.00
5. Stud, Nut & Bolts - 520.00 520.00
6. Wire Rope 1 45.00 45.00
7. Spring 10 30.00 300.00
8. Generator 1 220.00 220.00
9. Shaft 1 50.00 50.00
10 Packing And Pasting - 245.00 245.00
11. Galvanised Wire - 20.00 20.00

Sub.
Total: 6480.00

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Direct labour
Labour Cost - 800.00 Rs
Direct Manufacturing cost
Machining Cost - 2000.00 Rs.

6.3 TOTAL COSTING

Prime cost = Direct material + Direct labour + Direct Manufacturing cost
= 6480 + 800+ 2000
= 9280 Rs.
Over Head = 13% of Prime Cost
= (13/100) 9280
= 1206.40 Rs.
Total cost = Prime cost + Over Head
= 9280 + 1206.40
= 10486.40 Rs.

CHAPTER 7
ADVANTAGES

 This power can be stored in battery array so as to use it further

 This can be done using battery charging circuits and inverter circuits
 Can be installed at places such as cross over flyovers wherein mass
transit of pedestrians occurs e.g. Railway stations, bus stands,
squares etc.
 Can be use to provide electricity in local area
 Power can be stored for a period of time
 Circuit is monitored to ensure stable operation
 Can be couple to main grid in cities like Mumbai wherein probable
installation places are abundant
 Non conventional source of energy

 Saving of coal and water for generating electricity

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 Eco friendly, i.e., pollution free electricity generation

 Simple mechanism

 Easy for installation

 Easy for maintenance

 Be able to extract free renewable energy

 Energy is used only when needed
 Long term investment and maintenance is low
Can be installed in buildings or homes

CHAPTER 8
APPLICATION

It can be used in where huge amount of rush are frequently

comes like as :

 RAILWAY STATION: as the lacs of people travels from rail daily so we

implement this mechanism on the over bridge of railway station. Then
we can produce tremendous amount of electricity and save this energy
in batteries. We can use it as per the requirement. E.g. For lighting in
the night.

 AIRPORTS

 SHOPPING MALL

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 JOGGING PARK

 Flyover

CHAPTER 9
FURTHER IMPLIMENTATION

 We may divide each stairs into various segments, so that its

efficiency will be directly proportional to number of segments.

 We may patterning of two stairs and attach a fly wheel so that its
efficiency will be double, and as the number of similar parts will be
more , its cost will reduce.

 We may use of gear box of 1:100 ratio so that one revolution of

gears will move 100 times its pinion.

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CHAPTER 10
CONCLUSION

The project is developed keeping in mind the idea of generating

electricity from non-conventional means, which is free from pollution and
can be used directly in real life, i.e. it is not just a concept but a future

The project work displayed results as expected generating

electricity using staircase can prove very beneficial concept regarding
Indian context of view.

With further modification in this concept with some extent it can be

used for commercial purposes too. The best feature of the project is it
doesn’t use any running cost and is very much eco-friendly.

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REFERENCES

 http:// www.alternative-energy-news.info/ambient-energy-generator-
technology/ -

 http:// www.online-witness.com/Top/Science/273.html -

 http://www.societyofrobots.com/electronics_led_tutorial.shtml

 http://www.nedis.com/Articles/S.K.F./W1-04501.php

 http://dansbmx.co.uk/index.php?main_page=index&cPath=3_64

 http://www.physics4spm.com/2009/06/spm-physics-ac-generator.html

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 http://www.ehow.com/how_5768166_fix-irrigation-pipe.html

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