solenoid

for dc engine

1. 1

CHAPTER – 1
INTRODUCTION
1.1 Solenoid
A solenoid is a coil wound into a tightly packed helix. In physics, the term solenoid refers to
a long, thin loop of wire, often wrapped around a metallic core, which produces a magnetic
field when an electric current is passed through it. Solenoids are important because they can
create controlled magnet ic fields and can be used as electromagnets.The term solenoid refers
specifically to a magnet designed to produce a uniform magnetic field in a volume of space
(where some experiment might be carried out).

In engineering, the term solenoid may also refer to a variety of transducer devices that
convert energy into linear motion. The term is also often used to refer to a solenoid valve,
which is an integrated device containing an electromechanical solenoid which actuates either
a pneumatic or hydraulic valve, or a solenoid switch, which is a specific type of relay that
internally uses an electromechanical solenoid to operate an electrical switch; for example, an
automobile starter solenoid, or a linear solenoid, which is an electromechanical solenoid.


1.2 Magnetic field of a solenoid
Inside
This is a derivation of the magnetic field around a solenoid that is long enough so that fringe
effects can be ignored. In the diagram to the right, we immediately know that the field points
in the positive z direction inside the solenoid, and in the negative z direction outside the
solenoid.

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A solenoid with 3 Ampèrian loops
We see this by applying the right hand grip rule for the field around a wire. If we wrap our
right hand around a wire with the thumb pointing in the direction of the current, the curl of
the fingers shows how the field behaves. Since we are dealing with a long solenoid, all of the
components of the magnetic field not pointing upwards cancel out by symmetry. Outside, a
similar cancellation occurs, and the field is only pointing downwards.
Now consider imaginary the loop c that is located inside the solenoid. By Ampère's law, we
know that the line integral of B (the magnetic field vector) around this loop is zero, since it
encloses no electrical currents (it can be also assumed that the circuital electric field passing
through the loop is constant under such conditions: a constant or constantly changing current
through the solenoid). We have shown above that the field is pointing upwards inside the
solenoid, so the horizontal portions of loop c doesn't contribute anything to the integral. Thus
the integral of the up side 1 is equal to the integral of the down side 2. Since we can
arbitrarily change the dimensions of the loop and get the same result, the only physical
explanation is that the integrands are actually equal, that is, the magnetic field inside the
solenoid is radially uniform. Note, though, that nothing prohibits it from varying
longitudinally which in fact it does.

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1.3 Applications
a) Electromechanical solenoids

A 1920 explanation of a commercial solenoid used as an electromechanical actuator
Electromechanical solenoids consist of an electromagnetically inductive coil, wound around a
movable steel or iron slug (termed the armature).The coil is shaped such that the armature can
be moved in and out of the center, altering the coil's inductance and thereby becoming an
electromagnet. The armature is used to provide a mechanical force to some mechanism (such
as controlling a pneumatic valve). Although typically weak over anything but very short
distances, solenoids may be controlled directly by a controller circuit, and thus have very low
reaction times.
The force applied to the armature is proportional to the change in inductance of the coil with
respect to the change in position of the armature, and the current flowing through the coil (see
Faraday's law of induction). The force applied to the armature will always move the armature
in a direction that increases the coil's inductance.
Electromechanical solenoids are commonly seen in electronic paintball markers, pinball
machines, dot matrix printers and fuel injectors.
b) Rotary solenoid
The rotary solenoid is an electromechanical device used to rotate a ratcheting mechanism
when power is applied. These were used in the 1950s for rotary snap-switch automation in

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electromechanical controls. Repeated actuation of the rotary solenoid advances the snap-
switch forward one position. Two rotary actuators on opposite ends of the rotary snap-switch
shaft, can advance or reverse the switch position.
The rotary solenoid has a similar appearance to a linear solenoid, except that the core is
mounted in the center of a large flat disk, with two or three inclined grooves cut into the
underside of the disk. These grooves align with slots on the solenoid body, with ball bearings
in the grooves.
When the solenoid is activated, the core is drawn into the coil, and the disk rotates on the ball
bearings in the grooves as it moves towards the coil body. When power is removed, a spring
on the disk rotates it back to its starting position, also pulling the core out of the coil.
c) Rotary voice coil
This is a rotational version of a solenoid. Typically the fixed magnet is on the outside, and the
coil part moves in an arc controlled by the current flow through the coils. Rotary voice coils
are widely employed in devices such as disk drives.
d) Pneumatic solenoid valves
A pneumatic solenoid valve is a switch for routing air to any pneumatic device, usually an
actuator, allowing a relatively small signal to control a large device. It is also the interface
between electronic controllers and pneumatic systems.
e) Hydraulic solenoid valves
Hydraulic solenoid valves are in general similar to pneumatic solenoid valves except that
they control the flow of hydraulic fluid (oil), often at around 3000 psi (210 bar, 21 MPa, 21
MN/m²). Hydraulic machinery uses solenoids to control the flow of oil to rams or actuators to
(for instance) bend sheets of titanium in aerospace manufacturing. Solenoid-controlled valves
are often used in irrigation systems, where a relatively weak solenoid opens and closes a
small pilot valve, which in turn activates the main valve by applying fluid pressure to a piston
or diaphragm that is mechanically coupled to the main valve. Solenoids are also in everyday
household items such as washing machines to control the flow and amount of water into the
drum.
Transmission solenoids control fluid flow through an automatic transmission and are
typically installed in the transmission valve body.
1.4 Automobile starter solenoid
In a car or truck, the starter solenoid is part of an automobile starting system. The starter
solenoid receives a large electric current from the car battery and a small electric current from
the ignition switch. When the ignition switch is turned on (i.e. when the key is turned to start

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the car), the small electric current forces the starter solenoid to close a pair of heavy contacts,
thus relaying the large electric current to the starter motor.
Starter solenoids can also be built into the starter itself, often visible on the outside of the
starter. If a starter solenoid receives insufficient power from the battery, it will fail to start the
motor, and may produce a rapid 'clicking' or 'clacking' sound. This can be caused by a low or
dead battery, by corroded or loose connections in the cable, or by a broken or damaged
positive (red) cable from the battery. Any of these will result in some power to the solenoid,
but not enough to hold the heavy contacts closed, so the starter motor itself never spins, and
the engine does not start.
1.5 CONPONENT USED


1. Power transmitting dick
2. Bearing
3. Crank shaft (design)
4. Washer
5. Gearbox
6. Chain and sprocket
7. Wheel
8. Wheel shaft
9. Wire
10. Solenoid

6. 6

CHAPTER – 2
DC MOTORS & FAN REGULATER

2.1 DC motors

DC GEAR MOTOR
Brand HOSIDEN motors (Japan)
R.P.M: 75-100
VOLT: 12-18V. DC

One of the first electromagnetic rotary motors was invented by Michael Faraday in 1821 and
consisted of a free-hanging wire dipping into a pool of mercury. A permanent magnet was
placed in the middle of the pool of mercury. When a current was passed through the wire, the
wire rotated around the magnet, showing that the current gave rise to a circular magnetic
field around the wire. This motor is often demonstrated in school physics classes, but brine
(salt water) is sometimes used in place of the toxic mercury. This is the simplest form of a
class of electric motors called homopolar motors. A later refinement is the Barlow's Wheel.
Another early electric motor design used a reciprocating plunger inside a switched solenoid;
conceptually it could be viewed as an electromagnetic version of a two stroke internal
combustion engine.
The modern DC motor was invented by accident in 1873, when Zénobe Gramme connected a
spinning dynamo to a second similar unit, driving it as a motor.

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The classic DC motor has a rotating armature in the form of an electromagnet. A rotary
switch called a commutator reverses the direction of the electric current twice every cycle, to
flow through the armature so that the poles of the electromagnet push and pull against the
permanent magnets on the outside of the motor. As the poles of the armature electromagnet
pass the poles of the permanent magnets, the commutator reverses the polarity of the
armature electromagnet. During that instant of switching polarity, inertia keeps the classical
motor going in the proper direction. (See the diagrams below.)


A simple DC electric motor. When the coil is powered, a magnetic field is generated around
the armature. The left side of the armature is pushed away from the left magnet and drawn
toward the right, causing rotation.

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The armature continues to rotate.


When the armature becomes horizontally aligned, the commutator reverses the direction of
current through the coil, reversing the magnetic field. The process then repeats.
2.2 Fan Regulator
Description .This is the circuit diagram of the simplest lamp dimmer or fan regulator. The
circuit is based on the principle of power control using a Triac. The circuit works by varying
the firing angle of the Triac . Resistors R1, R2 and capacitor C2 are associated with this. The
firing angle can be varied by varying the value of any of these components. Here R1 is
selected as the variable element .By varying the value of R1 the firing angle of Triac changes
(in simple words, how much time should Triac conduct) changes. This directly varies the load
power, since load is driven by Triac. The firing pulses are given to the gate of Triac T1 using
Diac D1.
Notes
Assemble the circuit on a good quality PCB or common board. The load whether lamp ,fan or
any thing ,should be less than 200 Watts. To connect higher loads replace the Triac BT 136
with a higher Watt capacity Triac. All parts of the circuit are active with potential shock
hazard. So be careful.
I advice to test the circuit with a low voltage supply (say 12V or 24V AC) and a small
load (a same volt bulb) ,before connecting the circuit to mains.
Parts List
R1 1o K 1 Watt R

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CHAPTER -3
POWER SUPPLY & TRANSMITTING DICK

3.1 Battery
A 12-volt lithium battery is incredibly versatile, and can power a huge range of devices and
gadgets with the right accessories. The best thing, however, is that generally 12-volt lithium
batteries are completely rechargeable, and have a very long life span. This means that once
they are fully charged, you can get a great amount of use out of the more power-hungry
devices you might own, such as laptops or tablets. By picking up a 12-volt lithium battery
charger, you can make sure you always have power on tap wherever you go. Taking your
laptop camping for example, can be a very real possibility, and with a 12-volt lithium battery
pack, you can extend usage time even more by having a number of charged cells with you at
once. Finding the batteries and accessories is also simple thanks to the large inventory on
eBay.

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A wheel is a circular component that is intended to rotate on an axle bearing. The wheel is
one of the main components of the wheel and axle which is one of the six simple machines.
Wheels, in conjunction with axles, allow heavy objects to be moved easily facilitating
movement or transportation while supporting a load, or performing labor in machines.
Wheels are also used for other purposes, such as a ship's wheel, steering wheel, potter's wheel
and flywheel.

Common examples are found in transport applications. A wheel greatly reduces friction by
facilitating motion by rolling together with the use of axles. In order for wheels to rotate, a
moment needs to be applied to the wheel about its axis, either by way of gravity or by the
3.2 Solid-state relay
A solid state relay or SSR is a solid state electronic component that provides a function
similar to an electromechanical relay but does not have any moving components, increasing
long-term reliability. A solid-state relay uses a thyristor, TRIAC or other solid-state switching
device, activated by the control signal, to switch the controlled load, instead of a solenoid. An
optocoupler (a light-emitting diode (LED) coupled with a photo transistor) can be used to
isolate control and controlled circuits.

As every solid-state device has a small voltage drop across it, this voltage drop limits the
amount of current a given SSR can handle. The minimum voltage drop for such a relay is a
function of the material used to make the device. Solid-state relays rated to handle as much as
1,200 amperes have become commercially available. Compared to electromagnetic relays,
they may be falsely triggered by transients and in general may be susceptible to damage by
extreme cosmic ray and EMP episodes.[citation needed]

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A static relay consists of electronic circuitry to emulate all those characteristics which are
achieved by moving parts in an electro-magnetic relay.
A solid state contactor is a heavy-duty solid state relay, including the necessary heat sink,
used where frequent on/off cycles are required, such as with electric heaters, small electric
motors, and lighting loads. There are no moving parts to wear out and there is no contact
bounce due to vibration. They are activated by AC control signals or DC control signals from
Programmable logic controller (PLCs), PCs, Transistor-transistor logic (TTL) sources, or
other microprocessor and microcontroller control
application of another external force or torque.
3.3 Wire
A wire is a single, usually cylindrical, flexible strand or rod of metal. Wires are used to bear
mechanical loads or electricity and telecommunications signals. Wire is commonly formed by
drawing the metal through a hole in a die or draw plate. Wire gauges come in various
standard sizes, as expressed in terms of a gauge number. The term wire is also used more
loosely to refer to a bundle of such strands, as in "multistranded wire", which is more
correctly termed a wire rope in mechanics, or a cable in electricity.

Wire comes in solid core, stranded, or braided forms. Although usually circular in cross-
section, wire can be made in square, hexagonal, flattened rectangular, or other cross-sections,
either for decorative purposes, or for technical purposes such as high-efficiency voice coils in
loudspeakers. Edge-wound[1] coil springs, such as the Slinky toy, are made of special
flattened wire.

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CHAPTER – 4
BEARING

4.1 Bearings
s. Have you ever wondered how things like inline skate wheels and electric motors spin so
smoothly and quietly? The answer can be found in a neat little machine called a bearing.

A tapered roller bearing from a manual transmission
The bearing makes many of the machines we use every day possible. Without bearings, we
would be constantly replacing parts that wore out from friction. In this article, we'll learn
how bearings work, look at some different kinds of bearings and explain their common uses,
and explore some other interesting uses of bearings.

The Basics
The concept behind a bearing is very simple: Things roll better than they slide. The wheels on
your car are like big bearings. If you had something like skis instead of wheels, your car
would be a lot more difficult to push down the road.
That is because when things slide, the friction between them causes a force that tends to slow
them down. But if the two surfaces can roll over each other, the friction is greatly reduced.

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Bearings reduce friction by providing smooth metal balls or rollers, and a smooth inner and
outer metal surface for the balls to roll against. These balls or rollers "bear" the load,
allowing the device to spin smoothly.

4.2 Bearing Loads
Bearings typically have to deal with two kinds of loading, radial and thrust. Depending on
where the bearing is being used, it may see all radial loading, all thrust loading or a
combination of both.

The bearings that support the shafts of motors and pulleys are subject to a radial load.
The bearings in the electric motor and the pulley pictured above face only a radial load.
In this case, most of the load comes from the tension in the belt connecting the two pulleys.

The bearings in this stool are subject to a thrust load.
The bearing above is like the one in a barstool. It is loaded purely in thrust, and the entire
load comes from the weight of the person sitting on the stool.

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The bearings in a car wheel are subject to both thrust and
radial loads.
The bearing above is like the one in the hub of your car wheel. This bearing has to support
both a radial load and a thrust load. The radial load comes from the weight of the car, the
thrust load comes from the cornering forces when you go around a turn.
Types of Bearings
There are many types of bearings, each used for different purposes. These include ball
bearings, roller bearings, ball thrust bearings, roller thrust bearings and tapered roller thrust
bearings.
4.3 Ball Bearings
Ball bearings, as shown below, are probably the most common type of bearing. They are
found in everything from inline skates to hard drives. These bearings can handle both radial
and thrust loads, and is usually found in applications where the load is relatively small.

Cutaway view of a ball bearing

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In a ball bearing, the load is transmitted from the outer race to the ball, and from the ball to
the inner race. Since the ball is a sphere, it only contacts the inner and outer race at a very
small point, which helps it spin very smoothly. But it also means that there is not very much
contact area holding that load, so if the bearing is overloaded, the balls can deform or
squish, ruining the bearing.

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CHAPTER – 5
CRANKSHAFT & CHAIN SPROCKET
5.1 CrankShaft
A crankshaft is a mechanical part able to perform a conversion between reciprocating
motion and rotational motion. In a reciprocating engine, it translates reciprocating motion of
the piston into rotational motion; whereas in a reciprocating compressor, it converts the
rotational motion into reciprocating motion. In order to do the conversion between two
motions, the crankshaft has "crank throws" or "crankpins", additional bearing surfaces whose
axis is offset from that of the crank, to which the "big ends" of the connecting rods from each
cylinder attach.
It is typically connected to a flywheel to reduce the pulsation characteristic of the four-stroke
cycle, and sometimes a torsional or vibrational damper at the opposite end, to reduce
the torsional vibrations often caused along the length of the crankshaft by the cylinders
farthest from the output end acting on the torsional elasticity of the metal.

5.2 Crank Shaft Construction
Step-1
We are using ac solenoid coil in our project to give angular motion to our crank shaft.
Coil detail:
Brand: IDEAL -2.0kg/15mm rat,cont, a.c 220v



When we provide current to the coil it core.

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Step-2
We design special crank shaft according to the solenoid coil. We use three iron dicks and
pass iron rode from it as shown below diagram.
Use bearing (608) on both side of crank shaft for support it on base and we use chain and
sprocket for transmit power to gear box.

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Step-3
We attach solenoid coil with crank shaft as shown below.

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Step-4
We purchased one gear box of 1:4 ratios and fix in between crank shaft and wheel shaft for
providing torque to wheel.





Step-5

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We design our project as 4 stork solenoid engine. For distribution different four stork power
we using simple technique, we use metal sheet and cut it in circular form then we divide that
circle in to 4 different portions as shown below and paste on wooden circular piece.






Step-6
We make one hole in centre of that wooden piece and insert one dc gear motor in it. We
provide ac current to the motor shaft with help of insulator and attach one iron foil with that
shaft this foil is connected with on the other side as shown below diagram.

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We are running dc motor with help of dc supply and dc motor shaft is controlling ac current
with help of insulator and transmit power supply to solenoid coil for crank shaft movement.
5.3 Power supply of dc motor: we are using fan regulator for increase and decrease of
power supply which transmit to the 12v step down transformer. Now we receive 12 v ac
supply and we need 12dc supply so, we use bridge rectifier to convert ac to dc. As we
increase fan regulator speed our dc motor move fast, if we decrease its speed it move slow.
According to this our dick transmits power supply to solenoid coil and coil rotate to crank
shaft.

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Step-6
Final look of model

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CHAPTER – 6
GEAR BOX, WASHER & WHEEL

6.1 Gear box
Used gear box


6.2 Transmission (mechanics)
A Transmission or gearbox provides speed and torque conversions from a rotating power
source to another device using gear ratios. In British English the term transmission refers to
the whole drive train, including gearbox, clutch, prop shaft (for rear-wheel drive),
differential and final drive shafts. The most common use is in motor vehicles, where the
transmission adapts the output of the internal combustion engine to the drive wheels. Such
engines need to operate at a relatively high rotational speed, which is inappropriate for
starting, stopping, and slower travel. The transmission reduces the higher engine speed to the
slower wheel speed, increasing torque in the process. Transmissions are also used on pedal
bicycles, fixed machines, and anywhere else rotational speed and torque needs to be adapted.
Often, a transmission will have multiple gear ratios (or simply "gears"), with the ability to
switch between them as speed varies. This switching may be done manually (by the operator),
or automatically. Directional (forward and reverse) control may also be provided. Single-
ratio transmissions also exist, which simply change the speed and torque (and sometimes
direction) of motor output.

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In motor vehicle applications, the transmission will generally be connected to the crankshaft
of the engine. The output of the transmission is transmitted via driveshaft to one or more
differentials, which in turn drive the wheels. While a differential may also provide gear
reduction, its primary purpose is to change the direction of rotation.
Conventional gear/belt transmissions are not the only mechanism for speed/torque
adaptation. Alternative mechanisms include torque converters and power transformation.
6.3Uses
Gearboxes have found use in a wide variety of different—often stationary—applications, such
as wind turbines.
Transmissions are also used in agricultural, industrial, construction, mining and automotive
equipment. In addition to ordinary transmission equipped with gears, such equipment makes
extensive use of the hydrostatic drive and electrical adjustable-speed drives.
6.4 Wheel
A wheel is a circular component that is intended to rotate on an axle bearing. The wheel is
one of the main components of the wheel and axle which is one of the six simple machines.
Wheels, in conjunction with axles, allow heavy objects to be moved easily facilitating
movement or transportation while supporting a load, or performing labor in machines.
Wheels are also used for other purposes, such as a ship's wheel, steering wheel, potter's
wheel and flywheel.
Common examples are found in transport applications. A wheel greatly reduces friction by
facilitating motion by rolling together with the use of axles. In order for wheels to rotate,
a moment needs to be applied to the wheel about its axis, either by way of gravity or by the
application of another external force or torque.

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6.5 Washer
A washer is a thin plate (typically disk-shaped) with a hole (typically in the middle) that is
normally used to distribute the load of a threaded fastener, such as a screw or nut. Other uses
are as a spacer, spring (belleville washer, wave washer), wear pad, preload indicating device,
locking device, and to reduce vibration (rubber washer). Washers usually have an outer
diameter (OD) about twice larger than their inner diameter (ID).
Washers are usually metal or plastic. High-quality bolted joints require hardened steel
washers to prevent the loss of pre-load due to Brinelling after the torque is applied.
Rubber or fiber gaskets used in taps (or faucets, or valves) to stop the flow of water are
sometimes referred to colloquially as washers; but, while they may look similar, washers and
gaskets are usually designed for different functions and made differently.
Washers are also important for preventing galvanic corrosion, particularly by insulating steel
screws from aluminium surfaces.

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EXAMPLE
REVA
Mahindra Reva Electric Vehicles Private Limited, formerly known as the REVA Electric
Car Company,is an Indian company based in Bangalore, designing and manufacturing
electric vehicles. It is primarily notable for manufacturing the world's best selling electric
vehicle, the REVAi.

Company formation
The REVA Electric Car Company is a joint venture between
Maini Group of India and AEV LLC of California and
venture backed by lead US investors Global Environment
Fund and Draper Fischer Jurvetson.


REVA and REVAi
RECC currently produces two versions of the
REVAi, an urban electric micro-car seating two
adults and two children:A silver Reva REVAi,
equipped with lead-acid batteries, which has a
nominal range of 80 km (50 mi) per charge and a
top speed of 80 km/h (50 mph).
 REVA L-ion, equipped with Lithium-ion
batteries, which has faster acceleration
and a nominal range of 120 km (75 mi)
per charge.
The REVA has been sold in India since 2001 and in the UK since 2003. It is now available in
many other countries.
RECC also built in 2005 the REVA-NXG, a two-seater roadster concept car with a nominal
range of 200 km (124 mi) per charge and a top speed of 120 km/h (75 mph). It was planning
to release a roomier four-seater model by the end of 2009.
RECC also manufactures a Golf cart called FERI.

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Future
A new 30,000 capacity assembly plant in Bangalore has reached completion. It is currently
the world's largest operational example of a plant specially dedicated to the assembly of
battery electric vehicles. The entire building is LEED (Leadership in Energy and
Environmental Design) accredited allowing the company to boast one of the lowest dirt-to-
dust carbon footprints in the automotive world.
On 24 September 2009, RECC and General Motors India announced a collaborative
partnership to bring electric vehicles to the Indian market, however this plan was later
canceled due to REVA being bought by Mahindra & Mahindra Limited.
RECC is partnering with Bannon Automotive to set up a manufacturing base in upstate New
York to produce the NXR model.

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CONCLUSION
A Solenoid is a coil of wire,When current runs through that Coil of wire, creates a
electromagnet. Our project basically deals with the electromagnetic field concept which is
used to produce magnetic force to run the piston and that force transferred to the connecting
rod and ultimately it rotates crank shaft and that is how the engine delivers the requied
power. Solenoids are important for because they can create controlled magnetic fields and
can be used as electromagnet .Dc solenoids engine are very useful in automobile vehicle
because its maintenance cost is less as compared to the piston cylinder engine .Dc solenoid
engine involved complete elimination of pollutant emission &amount of power developed is
constant .this engine has less consumption of lubricating oil. It convert the magnetic energy
produced by solenoid into mechanical energy .

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REFERENCES

1) http://www.slidshare.net
2) http://www.wikipedia.com
3) http://www.seminarreport.net
4) http://www.nukephysik101.files.wordpress.com
5) http://www.cacoon.com
6) http://www.ridingmode.com
7) http://www.quora.com
8) http://www.pinterest.com
9) http://www.instructables.com

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PROJECT MEMBERS

MR. VARUN CHHABRA
(Project coordinator)





MR. AJAY KUMAR GUPTA
(Project Guide)

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ARYAN ANKIT






HARSH SHARMA



PRABHANJAN KR PANDEY

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RAHUL RAI




UPENDRA BHARDWAJ

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VIKASH SINGH