DESIGN AND EXPERIMENTAL EVALUATION OF A FLYWHEEL GENERATOR

Abstract

This study aims to design and fabricate a low-cost flywheel-assisted generator prototype to supply electrical power for basic loads in locations where access to electricity is unavailable. A series of experimental tests was carried out to validate its functionality.  The prototype was constructed using an 8 kg solid-steel flywheel attached to a 12 V DC automotive alternator. The other parts of the prototype include a sewing machine motor and belt drive, as well as other electrical components, i.e., a 12 V, 60 A battery and a 600 W DC-to-AC inverter. A 27 cm diameter flywheel was operated at approximately 2,100 rpm for operation. The results show that a DC voltage of 8.9-9.0 V and 60 A, corresponding to an electrical power of 534-540 W, at the alternator/ battery side. The prototype was reported to supply a 39 W fan, a 40 W lamp, and a 90 W motor, resulting in a simultaneous connected load of 179 W. The findings show a correlation between the prototype's mechanical feasibility and its ability to supply basic AC loads. However, these findings do not indicate net energy gain or continuous self-sustaining operation because the battery, motor input, conversion losses, and discharge duration were not measured as part of a complete energy balance. Therefore, this study contributes a practical small-scale prototype and identifies the measurements required for a more comprehensive future performance evaluation.