DESIGN AND FABRICATION OF A SOLAR POWERED

SOLENOID ENGINE

Submitted in partial fulfillment of the requirements for the award of

Bachelor of Engineering degree in Mechanical Engineering
By
TELU BHARGAV (37150193)
THOTA HARISH (37150194)

DEPARTMENT OF MECHANICAL ENGINEERING

SCHOOL OF MECHANICAL ENGINEERING

SATHYABAMA INSTITUTE OF SCIENCE AND TECHNOLOGY

(DEEMED TO BE UNIVERSITY)
Accredited with grade “A” by NAAC
JEPPIAAR NAGAR, RAJIV GANDHI SALAI, CHENNAI – 600119
APRIL 2021
 SATHYABAMA
INSTITUTE OF SCIENCE AND TECHNOLOGY
(DEEMED TO BE UNIVERSITY)
Accredited with “A” grade by NAAC
Jeppiaar Nagar, Rajiv Gandhi Salai, Chennai - 600 119
www.sathyabama.ac.in

DEPARTMENT OF MECHANICAL ENGINEERING

BONAFIDE CERTIFICATE

This is to certify that this Project Report is the Bonafide work of T BHARGAV (37150193) and
T HARISH (37150194) who carried out the project entitled “DESIGN AND FABRICATION OF
A SOLAR POWERED SOLENOID ENGINE’’ under my supervision from November 2020 to
April 2021.

Internal Guide
(Prof. R. DEVARAJ)

Head of the Department

(Dr. G. ARUNKUMAR, M.E., Ph.D.)

Submitted for Viva voce Examination held on

Internal Examiner External Examiner

 DECLARATION

We, T BHARGAV (37150193) and T HARISH (37150194) hereby declare that the Project
Report entitled “DESIGN AND FABRICATION OF A SOLAR POWERED SOLENOID
ENGINE” done by us under the guidance of Mr. R. DEVARAJ, is submitted in partial fulfilment
of the requirements for the award of Bachelor of Engineering degree in Mechanical
Engineering.

1.

2.

DATE: SIGNATURE OF THE CANDIDATES

PLACE: CHENNAI
 ACKNOWLEDGEMENT

We are pleased to acknowledge my sincere thanks to Board of Management of

SATHYABAMA for their kind encouragement in doing this project and for completing
it successfully. We are grateful to them.

We convey our thanks to Dr. S. Prakash, M.E., Ph.D., Dean, School of Mechanical
Engineering and Dr. G. Arun Kumar, M.E., Ph.D., Head of the Department,
Department of Mechanical Engineering for providing us necessary support and
detailsat the right time during the progressive reviews.

We would like to express our sincere and deep sense of gratitude to our Project
Guide Prof. R. DEVARAJ for his valuable guidance, suggestions and constant
encouragementpaved way for the successful completion of our project work.

We wish to express our thanks to all Teaching and Non-teaching staff members of
the Department of Mechanical Engineering who were helpful in many ways for the
completionof the project.
 TABLE OF CONTENTS

CHAPTER TITLE PAGE NO

NO
LIST OF FIGURES i
LIST OF TABLES ii
ABSTRACT iii
1 INTRODUCTION 1
1.1 Solenoid Coil 2
1.2 Plunger 2
1.3 Connecting Rod 3
1.4 Crankshaft 3
1.5 Spur Gear 4
1.6 Bearing 4
1.7 L-Brackets 5
1.8 Chain Drive 5
1.9 Screw and Bolt 5
1.10 Flywheel 6
1.11 Rechargeable Battery 6
1.12 Solar Panel 7
1.13 Relay 8
1.14 Transformer 9
1.15 Metal Proximity Sensor 9
1.16 PCB Board 10
2 LITERATURE SURVEY 11
3 AIM AND SCOPE OF THE PRESENT WORK
3.1 Aim of the present work 18
3.2 Scope of the Project 18
 3.3 Solar as a Power Source 18
3.4 Design of V-8 Solenoid Engine 19
4 FABRICATION METHODOLOGY
4.1 Methodology 20
4.2 Working 21
4.3 Calculations 23
5 RESULTS AND DISCUSSION
5.1 Results and Discussion 25
5.2 Advantages 26
6 SUMMARY AND OUTCOME OF THE PROJECT
6.1 Summary 27
6.2 Outcome of the project 27
REFERENCES 28
 LIST OF FIGURES

FIGURE No TITLE PAGE No

1.1 Solenoid 2
1.2 Plunger and Connecting Rod 3
1.3 Crankshaft 3
1.4 Bearing 4
1.5 Rechargeable Battery 7
1.6 Solar Panel 7
1.7 Relay 8
1.8 Transformer 9
1.9 Metal Proximity sensor 9
1.10 PCB Board 10
3.1 Front View of the Engine 19
3.2 Profile View of the Engine 19
4.1 Solenoid Engine 21
4.2 Electrical Circuit 22

i
 LIST OF TABLES

TABLE NO TITLE PAGE NO

5.1 Coil Testing Observation for 1000 turns Coil 25

ii
 ABSTRACT

Now a days, most of the internal combustion engines use petroleum products such
as diesel, gasoline. These chemicals during ignition liberates harmful gases like
Carbon dioxide (CO2), Carbon monoxide (CO), Sulphur dioxide (SO2), Polycyclic
aromatic hydrocarbons and Voltaic organic compounds into the earth’s atmosphere
and affects largely the nature. To bring down these destructive consequences on
environment the alternative source to these conventional internal combustion
engines are electrical engines. The main objective of the present work is to design
and fabricate a solar powered solenoid engine. This engine works on the principle of
electromagnetic induction. The system also reduces the fuel cost by using renewable
source of energy.

iii
 CHAPTER 1
INTRODUCTION
The advancement and production of electric vehicle is gradually increasing from the past few
years and continuous research is going on in this department to raise the efficiency and to
replace the existing theory. At present electric cars work with electric motors, accumulator is
used to store the energy.
The main moto of this work is to design a V8 solenoid engine that follows the concept of
electromagnetic induction. Solenoid is used as the replacement for the standard pistons that
are being used in internal combustion engines. V8 solenoid engine consists of eight solenoids
that power the engine. Here the electrical energy is converted into mechanical work. A
specific firing order is given to run the engine without any excessive load. Electricity is the
best alternative for the petroleum products to stop the emission. We use solar panel to charge
the batteries and obtain clean source of free energy to run the engine.
The main parts used in solenoid engine construction are:
• Solenoid Coil
• Plunger
• Connecting Rod
• Crankshaft
• Spur Gear
• Bearings
• Chain Drive
• Screw and Bolt
• Flywheel
• Battery
• Solar Panel
• Relay
• Transformer
• Metal Proximity Sensor
• PCB

1
1.1 SOLENOID COIL
If a coil of copper wire is used as an electromagnet, it is referred as a solenoid which
transforms electrical energy to mechanical energy when an electric current pass through the
coil that creates a magnetic field which can be used as a source for creating linear motion.
Solenoids are used in industries to control the flow of gases and liquids, automotive
applications, car washing machines.

Fig.1.1 Solenoid
The advantage of using electromagnet compared to permanent magnet is that the magnetic
field can be turned on when the power is supplied and this can be used as a switch making it
automatic.
The electromagnetic field of an activated solenoid has positive and negative poles that attract
or repel ferromagnetic material which allows the plunger to move back and forth. The solenoid
that is used here has 1000 copper turns and of 25 gauge. Capacity of the solenoid is of 12V.

1.2 PLUNGER
The plunger is assembled in a long cylinder solenoid, which can be moved back and forth
(push-pull). Plunger is made up of ferromagnetic material. The distance between the plunger
and the solenoid is equipped with a suitable seal. Without power, the plunger extends for a
part of its length outside the coil. When power is supplied magnetic field pulls the plunger into
the coil. Electromagnets with fixed cores are not considered solenoids.

2
1.3 CONNECTING RODS
Connecting rod connects the plunger with the crankshaft.

Fig.1.2 Plunger and Connecting Rod

1.4 CRANKSHAFT
A crankshaft is a shaft driven by the principle of crank mechanism, consisting of a series of
cranks and crankpins to which the connecting rods are connected. It is a mechanical part able
to perform a conversion from reciprocating motion to rotational motion.

Fig.1.3 Crankshaft

3
1.5 SPUR GEAR
Spur gears are most popular type of accuracy cylindrical gears. These gears feature a simple
design of straight, parallel teeth placed around the circumference of a cylindrical body with a
bore at the center fits over a shaft. In many variants, the gear is machined with a hub which
thickens the gear body around the bore without changing the gear face. The central bore can
also be put forward as to allow the spur gear to fit onto a spline or keyed shaft.
Spur gears are used in mechanical works to control the speed of a device or multiply torque
by transmitting motion and power from one shaft to another through a series of mated gears .
The structural design and construction of a spur gear will influence its performance. For
completing the work effectively and efficiently, gears need to be fabricated from quality
materials and with accurate dimensions. The dimensional measurements of each feature are
integral to how a specific gear function. As such, when an industry professional requires a
new spur gear design or a replacement spur gear, it is imperative that they are familiar with
the terms for each gear part and their respective measurements to ensure clarity and
accuracy in the production or purchase.

1.6 BEARING
Bearing is a mechanical element that converts relative motion to the desired motion, and this
reduces wear and tear between moving parts. The bearing design may give the free linear
motion of the moving part or it can provide free rotation around a fixed axis, it can prohibit
motion by controlling the vectors of normal forces that act on moving parts. Most bearings
provide the required motion by reducing friction. Bearings are divided into many types
according to the different operation.

Fig.1.4 Bearing

4
1.7 L - BRACKETS
An angle bracket is a L-shaped buckle used to join two parts at an angle 90-degree. Basically,
it is made of metal but it can also be made of wood or plastic. The metallic L-brackets
featured with holes to use screws. It is used to join a wooden shelf to a wall or to attach two
furniture parts together. In V shaped engine construction L-brackets are used to support the
pistons.

1.8 CHAIN DRIVE

Chain drive transmits mechanical power from one place to another place. It is often used to
transmits power to the wheels of a vehicle, basically motorcycles and bicycles. It is used in a
vehicle and machinery.
Roller chain is used to convey the power; it is known as the chain drive or transmission chain,
pass by a sprocket gear, with the teeth of the gear meshes with the holes at every links of the
chain. When the gear is turned, it pulls the chain and transfers mechanical force to the
system.
Periodically the power output is obtained by simply rotating the chain, which is used to drag
objects and lifting the weights. In some circumstances, the second gear is placed to recover
the power by connecting shafts or hubs to the gear. By changing the diameter of the both
input and output gears with reference to each other, we can also alter the gear ratio.

1.9 SCREW AND BOLT

Screw and Bolt are basically made of metal with helical ridge known as male thread. In
machine construction, usually a circular cylindrical member with helical rib as a fastener.
Screws are known for self-tapping when the screw is turned the thread cuts into the material,
it creates an internal thread that tends to pull fastened materials together and stops the pull-
out. There are many screws for a variety of materials; those commonly fastened by screws
include wood, sheet metal, and plastic. Bolts are related to screws which has internal thread
cut known as female thread.

5
1.10 FLYWHEEL
A heavy rotating metal wheel which is designed to store the rotational energy which is a form
of kinetic energy which is proportional to momentum of inertia and square of its rotational
speed. If the rotational speed is doubled the kinetic energy is quadrupled.
Once suitably abstracted, the principle of energy storage system can be generalized as
concept of an accumulator. In engine’s the flywheel helps to smooth out the vibrations of
energy obtained from during combustion in the cylinders. More precisely, a flywheel's stores
energy when the input power is high and this stored energy can be used when the input
power is low. Many reciprocating engine’s uses flywheels to produce more torque at each
piston.
Delivering energy at rates beyond the ability of an energy source. This is achieved by
collecting energy in a flywheel over time and then releasing it quickly, at rates that exceed
the abilities of the energy source. Most of the flywheels are made up of steel, cast iron and
these are rotated on bearings. These flywheels revolve at limited RPM. To attain high
revolving speed up to 60,000 RPM, it should be made up of carbon fiber material fixed with
magnetic bearings. The flywheel used here is 900 grams.

1.11 RECHARGEABLE BATTERY

A rechargeable battery is a type of electrical battery which can be charged and discharged
many times. It is made up of one or more electrochemical cells. The accumulator is a device
that is used to store energy and also used to transfer it by the process of electrochemical
reaction. Rechargeable batteries can be manufactured in many shapes and sizes, ranging
from megawatt systems to button cells used to stabilize an electrical distribution network.
There are different combinations of electrode materials and electrolytes, including lead–acid,
zinc-air, NiCd, NiMH, Li-ion, LiFePO4, Li-ion polymer.
The energy used to charge rechargeable batteries usually comes from a battery charger using
AC mains electricity, although some are equipped to use a vehicle's 12-volt DC power outlet.
The voltage of the source must be higher than that of the battery to force current to flow into it,
but not too much higher or the battery may be damaged.
12volt rechargeable battery is used as a power source.

6
 Fig.1.5 Rechargeable Battery

1.12 SOLAR PANEL

The photo-voltaic (PV) cell can be termed as solar panel. A framework of solar panel can be
installed by placing photo-voltaic cell in a single module. Sunlight is used as a source of
energy for Photo-voltaic cells and generate electricity. A group of PV modules is called a
Solar Panel, and a system of panels is known as array. Arrays of a photovoltaic system
supply solar electricity to run electrical appliances.

Fig.1.6 Solar Panel

Photovoltaic modules use photons which are emitted from the Sun to produce electricity
through the photovoltaic effect. wafer-based crystalline silicon cells are used in most of the
modules. The load carrying member of a module could be either the bottom layer or the top
layer. Cells must be prevented from physical damage and water moisture. Most modules are
hard, but the thin-film cells which are semi-flexible in nature are also available. A desired
voltage can be obtained by connecting the cells in series, and to increase amperage they
7
 must be connected in parallel. The module wattage can be calculated mathematically by
voltage and ampere that are obtained in the module. The power output of the solar panel is
different from manufacture specifications because they are obtained in laboratory conditions
while operating in physical condition it depends on sunlight that exposed on panel.
• Model – ASP - 12- 25
• Panel Dimension - 555 * 340 mm
• Cell Type - Poly crystalline
• Maximum power (Pmax) - 25W
• Voltage at minimum power (Vamp) - 17.6V
• Current at maximum power (Iamp) - 1.42A
• Open circuit voltage (Voc) - 21.5V
• Short circuit current (Isc) - 1.53A
• Panel efficiency - 13.2%
• Operating Temperature - 40 to 85 degree centigrade

1.13 Relay
Through the coil of the relay, an electrically powered switch, flowing current creates the
magnetic field that initiates a lever to change the switch contact. In the present work, 30
amps relay switch is used.

Fig.1.7 Relay

8
1.14 Transformer
A transformer is known as passive electrical device. The process of electromagnetic induction
is used in transformer that transfers electrical energy from one circuit to another circuit. This
device is used to step up or step down the voltage levels between circuits.

Fig.1.8 Transformer

1.15 Metal Proximity Sensor

This sensor works on the principle of eddy currents. Metal proximity sensor can only detect
metal targets. They cannot detect non-metal targets such as plastic, wood, paper, and
ceramic. Inductive proximity sensors can detect a metal object via opaque plastic, unlike
photoelectric proximity sensors.

Fig.1.9 Metal Proximity Sensor

9
1.16 PCB board
It is used to connect all the electronic components using conductive pathways. It receives
signal from the LDR sensor and controls movement of parabolic trough through the worm
gear box arrangement.
For the present system, PCB board with relays and IC’s is used. All the required electronic
components are connected to this board by soldering.

Fig.1.10 PCB Board

Advantages of PCB board:
Compact size and saving of wire.
Short circuits can be avoided.
Low cost and highly reliable.

10
 CHAPTER 2

LITERATURE SURVEY

1.Title: Design and Fabrication of an Electromagnetic Piston Engine

Journal: International Research Journal of Modernization in Engineering Technology and
Science
Author: Sanith Vaddepalli , Preetham N M, Ashish B Karanth
Year: 2020
Description
The electromagnetic piston engine is a type of reciprocating engine that operates on the
electromagnetism principle, which states that like poles attract and unlike poles repel. The
piston, connecting rod, cylinder, and crankshaft are all present in the engine, just as they are
in a traditional engine. A neodymium magnet is fixed to the top of the piston since it is a very
strong magnet. The piston attracts the solenoid from BDC to TDC as the magnet and solenoid
have opposite poles. The solenoid repels and moves the piston from TDC to BDC until it
switches poles and becomes the same pole as the magnet. This paper's engine is a four-
cylinder V4 configuration engine. As a result of this experiment and project, this engine cannot
currently be used to lift high-power loads or for significant vehicular applications. However,
this engine can be improved in any way, and with continued improvement, it could soon be
seen as a viable alternative to the current engine.
Conclusion
For the most part, the solenoid piston engine is based on the concept of a traditional IC
engine. The solenoid replaces the engine's cylinder, and the piston is fitted with a high-power
neodymium magnet. The engine works similarly to an IC engine, and it can be configured in
any way that an IC engine can be configured. This engine is still in its infancy. As it stands,
the engine produces low rpms and has a 20 percent lower performance than the IC engine.
However, the most important thing to note is that the engine is powered by electricity and is
therefore better in terms of environmental factors than traditional IC engines. The engine is
inoperable. The piston is devoid of piston rings, and a solenoid replaces the traditional valves
and ports in the cylinder head. The rest of the parts, such as the crankshaft, configuration,
and flywheel, remain unchanged. The engine can power autonomous low-speed vehicles and
has a lot of space for advancement in the future. This is one of the possible replacements for
IC engines with adequate power.
11
2.Title: Design and Development of V8 Solenoid Engine
Journal: International Research Journal of Engineering and Technology
Author: Sarthak Raisoni
Year: 2020
Description
The engine is the primary source of power in a car, and the vast majority of engines today are
Internal Combustion (IC) engines that run on either gasoline or diesel. When these fuels are
burned in the piston, heat energy is released, which is then converted into mechanical energy.
After combustion, these fuels emit toxic gases, polluting the atmosphere and having
detrimental effects. Fossil fuels will be depleted in the near future, and Electric Cars are
currently the perfect alternative to gasoline-powered vehicles. Electricity is a pollution-free
energy source with virtually no emissions. The aim of this project is to create a solenoid
engine that operates on the electromagnetism principle. This principle is applied to the
conversion of electrical energy to mechanical energy.
Conclusion
The aim of the project is to make an electric vehicle that is powered by a group of solenoids
function efficiently. A battery is used to provide current to the solenoid as well as to power the
auxiliaries found in automobiles. The piston is based on the solenoid concept, and the power
train is based on the IC engine. This idea is proposed in light of the steadily rising prices of
fossil fuels and the emissions they cause. It will require a higher initial investment than
traditional gasoline-powered vehicles, but it will prove to be more effective and cost less in the
long run.

3.Title: Design and Fabrication of 4-Stroke Solenoid Engine

Journal: International Research Journal of Engineering and Technology
Author: Anamika Tiwari, Anurag Singh, Deepak Agarwal and Ajay Kumar Verma
Year: 2019
Description
In present investigation we have designed a solenoid coil engine based on Induction principle
which is alternate option of electric Engine in future due to it high load carrying capacity and
low cost as compared to electric engine. Through this work new advanced automobile cum
electrical technology is implemented to regenerate a new advance electric engine without
using a motor and it is possible to totally remove the motor from car which we name as high
12
torque coil engine. It works like a normal fuel engine but now power source is battery with is
totally pollution free and eco-friendly.
Conclusion
The four-stroke solenoid engine has been designed and fabricated We have measured the
speed at the wheel and at the crankshaft using tachometer successfully. The project was
mainly concerned with fabricating a revolutionary engine that runs with the help of solenoid
coil. Basically, it’s advancement to the electric vehicles where electric motor is used to run the
engine but, in our project, we have used solenoid coils in order to increase the battery life and
eliminate the losses of the electric motor so as to augment the power output. It has been cost
effective as the design is much simpler than the conventional engines of electric vehicle. No
cooling is required and many other parts such as valves, cam, ports etc. were eliminated. It
can be concluded that the test engine is simple to run the electric vehicle efficiently and if
used at a large-scale production by considering the recommendations mentioned in the future
scope the power, speed and efficiency can be enhanced to a greater extent.

4.Title: Design, Analysis and Manufacturing of a V8 - Solenoid Engine

Journal: International Journal of Engineering Research and Technology
Author: Ruthwik Aki, N. V. Dharma Teja, K. S. V. Phanindra, Setty Siddhartha
Year: 2019
Description
In an automobile, the engine is the primary power source, in which fuel is burned and heat
energy is emitted, which is then transformed into mechanical energy. When fuel is burned,
toxic gases are emitted, resulting in air pollution. Electric vehicles are being built these days.
For power generation, we prefer electromagnetic engines. We presented the design, as well
as an analysis, in this paper.
Conclusion
Based on our estimates, we have a 21.44 percent efficiency, which can be improved by
improving the design and choosing appropriate materials that work well under the specified
conditions, i.e., making the mechanisms more fluid and therefore reducing friction and
stresses. With that said, the new solenoid coils are constrained by a high drop in efficiency
caused by the coils' unwanted heat generation. Even if this phenomenon is used for other
applications, as in a traditional Combustion Engine, we are limited to today's technical
advances to increase performance, but this model shows great promise for the future.

13
5.Title: Design and Fabrication of Solenoid Engine
Journal: International Journal of Modern Engineering Research.
Author: Ram Bansal, Rahul Kushwah, Divya Pawar
Year:2019
Description
As we move toward becoming a developed world, the demand for fossil fuels increases.
Hence an alternative to fossil fuel is the present requirement. The internal combustion engine
pollutes the environment. As a consequence, the electromagnetic field was invented to solve
this problem.
Conclusion
The electromagnet's windings loosened up with repeated handling, increasing the gaps
between the windings. This results in a decrease in potential energy from the power source
band, which prevents successful magnetic flux generation. It's also worth noting that the
permanent magnet's energy is greater than that of an electromagnet. The engine will be built
with materials that have a high strength-to-weight ratio.

6.Title: Solenoid Engine

Journal: International Journal of Advance Engineering and Research Development.
Author: Fanse Mayur N, MachhiJeet Kumar B, Panchal Prashit Kumar D.
Year: 2017
Description
This paper focuses on reducing the use of large fossil fuels and increasing the use of
renewable energy sources. Using a solenoid engine, it is possible to reduce emissions and
save electricity in the future. The use of electromagnetic engines reduces air emissions and
allows for environmentally sustainable activity. The current challenge is to make them more
cost-effective by making them more powerful and comfortable. The friction of the engine in
this engine is high.
Conclusion
The pentagonal engine structure is presented in this work. We may build the structure with
more sectional design in the future for more power and torque output, similar to a V8 or V12
engine with more powerful power output. The use of non-renewable resources is limited as a
result of this and similar systems, and potential energy can be conserved.

7.Title: Solenoid engine

14
Journal: Indian Journal of Research
Author: Dr. Vijay Kumar, Anurag, Ankit Kusum, Aditya Nadh Yadav
Year: 2017
Description
The purpose of this work is to design and construct an electromagnetic engine. This engine
differs from internal combustion engine because of its operating principle as this engine works
on electromagnetic principle instead of combustion of fossil fuels.
Conclusion
The working of a magnetic piston engine differs from other engines. This engine does not use
gasoline a s a result there is no pollution. Since ignition is absent, only a small amount of
heat energy is generated, making it cost-effective.

8. Title: Emission less Engine by using electromagnet.

Journal: International Journal of Advance Engineering and Research.
Author: C. Sudhakar, K. Premkumar, K.Vijith, S.Balaji,
Year: 2014
Description
The purpose of this work is to build an electromagnetically reciprocating car motor. The
vehicle is driven by a four-stroke mechanism. Although the plunger is a movable permanent
magnet, the top of the cylinder is fixed by an air core electromagnet. The magnets repel for
the same polarities and attract for the opposite polarities, allowing the piston to travel back
and forth.
Conclusion
From this paper they tried to implement v-type engine that consist of two permanent and
electromagnet respectively that works as per the magnetic principle, which can give better
output.

15
9.Title: Electromagnetic Reciprocating Engine.
Journal: International Journal of Engineering Trends and Applications.
Author: Kala Butler.
Year: 2014
Description
Businesses have been searching for ways to reduce their reliance on oil. Oil supplies are
depleting, and demand is rising in tandem with the price. The Electromagnetic Reciprocating
Engine, which owns the patent for electromagnetic engine, will replace the Combustion
Engine.
Conclusion
In a generator the electromagnetic reciprocating engine will replace the combustion engine
resulting in green renewable energy. The electromagnetic reciprocating engine has a 12-year
maintenance period and a low running cost. The electromagnetic reciprocating engine has the
ability to replace the use of fossil fuels in transportation and power generation for homes and
businesses.

10.Title: A Literature Review on Hybrid Electric Vehicles.

Journal: International Journal of Engineering Research & Technology.
Author: M. Viswanath, K. M. Arunraja, K. Lakshan Raaj.
Year: 2014
Description
In a generator the electromagnetic reciprocating engine will replace the combustion engine
resulting in green renewable energy. The electromagnetic reciprocating engine has a 12-year
maintenance period and a low running cost. The electromagnetic reciprocating engine has the
ability to replace the use of fossil fuels in transportation and power generation for homes and
businesses.
Conclusion
Hybrid-electric vehicles (HEV) combine the advantages of internal combustion engines which
electric motors, and can be designed to achieve a variety of goals, including increased fuel
efficiency, increased capacity, and additional auxiliary power for electronic devices and power
tools. Power transmission through freewheels and chain wheels is both inexpensive and
dependable. One downside is that driving on electric power is not a feasible long-distance
alternative. Though in more stop-and-go traffic conditions, this hybrid power train system
could be very useful.
16
11.Title: A Review Paper on the Study of 4-Stroke Solenoid Engine.
Journal: International Research Journal of Engineering and Technology.
Author: Anamika Tiwari, Abhishek Tiwari.
Year: 2014
Description
In this paper, we look at a solenoid engine that uses a solenoid actuator to drive the engine
instead of burning gasoline, as in an internal combustion engine, and an electric motor in an
electric vehicle. Essentially, this engine operates on the basis of electromagnetism. We chose
to drive the engine to provide an alternative to the electric motor in an electric vehicle using
the electromagnetism concept to compensate for various losses and prevent rapid battery
drain. It functions similarly to a traditional gasoline engine, except the power source is now a
battery, which is completely pollution-free and environmentally friendly.
Conclusion
This cutting-edge technology allows for the sustainable extraction of energy while also
reducing emissions to zero, resulting in a significant reduction in pollution. It was cost-
effective because the architecture is much simpler than traditional electric vehicle engines.
There is no need for cooling, and many other components such as valves, cams, and ports
have been removed. we can come to the conclusion that the proposed engine is an easy and
effective method for operating an electric vehicle efficiently, and that if used in large-scale
production, the power, speed, and efficiency can be increased to a greater extent by taking
into account the recommendations stated in the future scope.

17
 CHAPTER 3

AIM AND SCOPE OF THE PRESENT WORK

3.1 AIM OF THE PRESENT WORK

The main aim of the present work is to reduce greenhouse effect. In conventional engines
petrol and diesel are used as their main fuel source and release pollutants. The objective of
the work is to design and fabricate solar powered solenoid engine. That is constructed on
traditional v-8 model. The basic principle used in solenoid engine is electromagnetism. The
electrical energy is supplied to the solenoid which pushes the plunger to rotate the shaft.
Battery is the power source for the engine. Batteries are charged using solar cells.

3.2 SCOPE OF THE PROJECT

The idea of this prototype is to use the property of an electromagnet. By changing the
direction of current flowing through the solenoid we can change the polarity of the poles. The
permanent magnet attached to the plunger is attracted or repelled by polarity difference. The
performance of the engine can be improved by adding more permanent magnets in series,
thus improving its efficiency, so that it can be used in heavy vehicles and other applications.

3.3 BACKGROUND OF SOLAR AS A SOURCE

Solar energy has always been a great source of energy due to its low cost and the unlimited
existence of the sun. However, energy source that comes from natural resources are
decreasing and some of them may become extinct source of energy in the future. So, we are
using the most abundant source of energy as the power input to the solenoid engine.

18
3.4 DESIGN OF V-8 SOLENOID ENGINE

Fig.3.1 Front View of the Engine

Fig.3.2 Profile view of the Engine

19
 CHAPTER 4
FABRICATION METHODOLY
4.1 METHODOLOGY
• A design of the engine is made using Autodesk Fusion 360 software. The parts to be
fabricated and the parts to be procured are to be identified and a market survey has to be
done in order to identify the cost of these parts. The required parts have to be procured based
on the design calculations.
• At first, base frame of approximately 860x460 mm is constructed.
• Crank shaft is fixed in the frame using bearing support. The crank shaft is customized as per
design calculations.
• Flywheel is connected to the crankshaft and the speed of the engine is measured here.
• Crank shaft is connected to piston through link rod which leads to the movement of the
crankshaft.
• Based on the requirement of input power, solenoid of 12V is constructed and coupled with
crank shaft.
• An electronic based control unit is wired with solenoid and a proximity sensor is used to get
the feedback.
• Now each crank is operated as per the firing order of the solenoids and the power output from
the solenoid engine is obtained and the efficiency of the engine is computed.

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4.2 WORKING
The electromagnetic attraction is the basis of the solenoid engine. It is an electromagnetic unit
that uses coil magnetism to drive the plunger. A magnetic field is created around a conductor
when an electric current is applied to it, and the conductor serves as an electromagnet. The
current flowing through the coil, as well as the number of turns wound on the coil, are used to
quantify the electromagnetic power. As current flows through the coil, it behaves like an
electromagnet, and the motor is controlled using the magnetic attraction and repel principle. A
piston reciprocates within a nonmagnetic cylinder that is open to the atmosphere in the
mechanical sub-system. A connecting rod attached the piston to a crankshaft, allowing for
rotary output. A magnet was placed at the top surface of the piston as part of the system.
During reciprocating motion magnets travelled along with the piston. Magnets followed the
piston during reciprocating motion.

Fig.4.1 Solenoid Engine

The pole orientations of the magnets were oriented in the same direction. The north poles of
both magnets would be exposed to the atmosphere if the south poles of both magnets were
fixed to the piston rim. As current passes through a solenoid, it creates a dipole on both ends,
resulting in the formation of the north and south poles. The energy was supplied by a normal
Li-ion battery with a voltage of 12V.
The piston is attracted as current is passed through one of the solenoids. The nonmagnetic

21
cylinders were covered with the copper wire which acts as an electromagnet. It was fixed in
place by a rigid frame made up of differential positioning arrangements. The controlling circuit
is made up of two proximity sensors placed at TDC and BDC each of them senses the
movement of both pistons separately. When Piston 1 is at BDC, the proximity sensor sends
the signal to PCB and it actuates the relay. By using relay the solenoid is charged in such a
way that the poles of the electromagnet are opposite to the Permanent Magnet 1, creates an
external force on the piston. The continuous process can be achieved by rotating the flywheel
with relay and metal proximity sensors. The regulating circuit was in charge of switching the
direction of current in the electromagnet. When the piston approaches BDC, the sensors are
positioned in such a way that they have a high performance.
Solar panels are used as main power source which is connected to battery by using battery
controller. This controller helps to connect the solar panel and battery.

Fig.4.2 Electrical Circuit

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4.3 CALCULATIONS
These calculations are done on exemplary basis
Voltage input (Vi) = 12 Volts
Current input (Ii) = 1 Amps
Power input = Vi × Ii = 12 × 1 = 12Watts
Max. Force exerted by electromagnet on piston
F1 = (N2×I2×K×A)/(2×G2)
Where, N = number of turns = 1000
I = Current through coil = 1 A
K = Permeability of free space = 4π×10-7
A = C/S area of electromagnet (radius r = 0.0175m)
G = Least distance between electromagnet and permanent magnet = 0.005 m
We get,
Max. Force F1 = 24.127 N
Force exerted by permanent magnet Force F2
F2 = (B2×A)/2µ0
Where, B = Flux density (T)
A = Cross-sectional area of magnet (radius r = 0.0125 m)
µ0 = Permeability of free space = 4π×10-7
Now flux density B = Br /2 × [(D + z)/ (R2 + (D + z)2)0.5 – z/ (R2 + z 2) 0.5] Where,
Br = Remenance field = 1.21T
Z = distance from a pole face = 0.005 m
D = thickness of magnet = 0.012 m
R = semi-diameter of the magnet = 0.0125m
On substitution we get flux density, B = 0.2568 T
Now substituting B in the equation of force, F2 = 12.67 N
Since, force F1 and F2 are repulsive,
Total force F = F1 + F2
F = 36.8
Torque T = F × r
r = Crank radius = 0.01m
Torque T = 0.3685 N-m
Mass of Fly wheel ω = (2×π×N)/60,

23
where N = Speed = 200rpm
Therefore ω = 20.94 rad/s
Energy stored on flywheel E = T × θ
Where T = torque θ = Angle of rotation = π radians
On substitution, the energy stored E =1.157 J
E = 0.5×I×ω2
Where, I = Moment of inertia of flywheel
ω = Angular velocity
On substitution we get moment of inertia, I = 5.277 ×10-7 Kg-m2
Moment of inertia,
I = 0.5×m×r2
Where, m = Mass of fly wheel
r = Radius of fly wheel = 0.07 m
m = 2.154 Kg
Output power
P=(2×Π×N×T/60)
Where, N = Speed = 200 rpm
T = Torque = 0.3685 N-m
On substitution, Output power P = 7.718 W
Efficiency = (Output/Input) ×100= (7.718/36) ×100}
Therefore,
Efficiency = 21.44

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 CHAPTER 5

RESULTS AND DISCUSSION

5.1 Results and Discussion

An electromagnetic piston engine is one that operates on the magnetism principle, in
which like poles attract and unlike poles repel each other. An engine with V8
configuration was designed based on this. The following findings were observed.
1. This engine has a low power input to high power output ratio. A higher load
carrying capacity solenoid will provide more power to the engine but it will increase
the size of the engine significantly.
2.This engine cannot handle heavy loads on its own as the load carrying capacity of
the solenoid used in this engine is limited.
3. Vibration and noise of the engine can be reduced by mounting a flywheel which
makes the engine to run smoothly at constant speed.
4. The load carrying capacity of this engine can be increased by gear mechanism
which improves the engine speed and its performance.
5. Solenoid engines architecture is simpler and lighter as it has no valves and ports.
This reduces the maintenance cost of the engine and also it minimizes the
lubrication.
6. This engine can be used to power light unmanned vehicles where the speed of the
engine is not important. This can be used where solar power is aplenty.
7. For solenoid coil testing, 28-gauge copper conductor with 1000 turns is taken. By
varying the input current in the coil, the magnetic force can be increased and the
plunger movement is observed as shown below.
Table 5.1 Coil Testing Observation for 1000 turns coil
Serial No. Current Movement of Plunger

1 1.2 Amp Attraction

2 3.5 Amp Rapid Attraction

3 6.5 Amp Strong Attraction

8. This engine use solar energy thereby fossil fuel consumption can be greatly
25
reduced and hence the global warming can be minimized.
9. This work has a lot of scope for improvement in its design and performance as two
solenoids, one at the top and other at the bottom of the piston can be added.
5.2 Advantages of solenoid engine
• It has less running cost than an internal combustion engine.
• It does not create pollution and can reduce global warming.
• It takes less amount of energy from the battery for every revolution of the
crankshaft.

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 CHAPTER 6

SUMMARY AND OUTCOME OF THE PROJECT

6.1 SUMMARY
Based on the performance calculation, the efficiency is found to be 21.44%, which
can be improved by improving the design and choosing appropriate materials that
work well under the specified conditions, i.e., making the mechanisms easier and
therefore reducing friction and stresses. The current solenoid coil has drop in
efficiency due to the heat generated by the coil. The same phenomenon is observed
in internal combustion engine and in order to increase the efficiency, the cooling
process has to be improved.

6.2 OUTCOME OF THE PROJECT

A working model of a solenoid engine is designed and constructed which works on
the principle of electromagnetism. The combination of eight electromagnetic coils
and a specially built crankshaft results in emission-free operation. This device needs
further improvement before it can be used for various industrial applications.

27
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11. Anamika Tiwari, Anurag Singh, Deepak Agarwal, Ajay Kumar Verma, “Design and
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