Shivnagar Vidya Prasarak Mandal’s

INSTITUTE OF TECHNOLOGY & ENGINEERING

Malegaon (BK), Tal- Baramati, Dist – Pune.
Pin :- 413115, Ph :- (02112-254214, Fax :- 254424).

PROJECT REPORT

ON

“ALTERNATOR BASED SELF CHARGING ELECTRIC

CAR”

SUBMITTED BY

Mr. DAHIBHATE ANIRUDDHA SACHIN 2200380170

Mr. MALSHIKARE TUSHAR PRAKASH 2200380172
Mr. PAWAR SUHAS KAUSHIRAM 2200380182
Mr. SHAIKH ABUJAR TAIYYAB 2200380186
Mr. GIRAME KARAN DILIP 2100380193

UNDER THE GUIDANCE OF

Prof. A. R. SHELAR

DEPARTMENT OF AUTOMOBILE ENGINEERING

I.T.E. MALEGAON (BK.)

[SESSION 2024-2025]

i
 Shivnagar Vidya Prasarak Mandal’s
INSTITUTE OF TECHNOLOGY AND ENGINEERING
Malegaon (Bk.), Tal:Baramati, Dist: Pune, Pin:413115.

CERTIFICATE
This is to certify that project report entitled “ALTERNATOR BASED
SELF CHARGING ELECTRIC CAR’’ Submitted in the partial
fulfillment of requirement for the award of Diploma in Automobile
Engineering by Maharashtra State Board of Technical Education,
Mumbai – 51.

SUBMITTED BY

Mr. DAHIBHATE ANIRUDDHA SACHIN 2200380170

Mr. MALSHIKARE TUSHAR PRAKASH 2200380172
Mr. PAWAR SUHAS KAUSHIRAM 2200380182
Mr. SHAIKH ABUJAR TAIYYAB 2200380186
Mr. GIRAME KARAN DILIP 2100380193

Prof. A. R. SHELAR Prof. S. M. TAWARE

(Guide) (H.O.D.)

Prof. SHAHA S. R.
(Principal)
ITE MALEGAON BK.

DEPARTMENT OF AUTOMOBILE ENGINEERING

I.T.E. MALEGAON BK.

[SESSION 2024-2025]

ii
 Shivnagar Vidya Prasarak Mandal’s
INSTITUTE OF TECHNOLOGY AND ENGINEERING
Malegaon (Bk.), Tal:Baramati, Dist: Pune, Pin:413115.

CERTIFICATE
This is to certify that project report entitled “ALTERNATOR BASED
SELF CHARGING ELECTRIC CAR” submitted in the partial
fulfillment of requirement for the award of Diploma in Automobile
Engineering by Maharashtra State Board of Technical Education,
Mumbai–51.

SUBMITED BY

Mr. DAHIBHATE ANIRUDDHA SACHIN 2200380170

Mr. MALSHIKARE TUSHAR PRAKASH 2200380172
Mr. PAWAR SUHAS KAUSHIRAM 2200380182
Mr. SHAIKH ABUJAR TAIYYAB 2200380186
Mr. GIRAME KARAN DILIP 2100380193

Signature Signature

(Internal Examiner) (External Examiner)

DEPARTMENT OF AUTOMOBILE ENGINEERING

I.T.E. MALEGAON BK.
[SESSION: 2024-2025]

iii
 ACKNOWLEDGEMENT

We have great pleasure in delivering the project on the topic, “ALTERNATOR

BASED SELF CHARGING ELECTRIC CAR”. This project has helped me to express
the extracurricular knowledge with incredible help and inspiring guidance from Prof. A.
R. SHELAR (Department of Automobile Engineering), we sincerely thanks. more than
what we can express, towards Prof. S. M. TAWARE (Head of Automobile Engineering
Department), as all the result of his affectionate encouragement.
We are grateful to Prof. S. R. SHAHA (Principal of ITE Malegaon Bk.) for his
encouragement and for giving us guidance and valuable time for the discussion. We
express our sincere thanks to all the staff, parents and colleagues who have helped us
directly in completing this project.
We also thanks to Mr. Amarsinh Shinde (Baba) for his guidance and needful help
in making & printing project.
We are grateful for the many useful comments and suggestions provided by
reviewers, which have resulted significant improvements in project.

Mr. DAHIBHATE ANIRUDDHA SACHIN 2200380170

Mr. MALSHIKARE TUSHAR PRAKASH 2200380172
Mr. PAWAR SUHAS KAUSHIRAM 2200380182
Mr. SHAIKH ABUJAR TAYYAB 2200380186
Mr. GIRAME KARAN DILIP 2100380193

Date: / / 2025

Place: Malegaon (Bk.)

iv
 ABSTRACT
This project relates to the functioning of an electric car with self charging from alternator
to the battery. The alternator produces the electricity while the wheel is moving, allowing
the alternator to move with the wheel friction. In this paper, we take all the components
of alternators that include a DC-DC converter, motor, battery and controller. Alternator
gets the drive from friction. Here the alternator has the ability to generate the 14V DC,
which is directly connected to the DC-DC converter throughout the battery. The dc-dc
converter has the ability to step up to the 18V and that is enough to charge four batteries
which are connected into the series connection that produces the 13V supply. Controller
gets connected to the battery, motor and another connection.
This project gives solution to the old problems, where the most common problem arising
from existing electric car is the recharging system. The conventional system leads to
consume more conventional power and time. Hence our project reduces the problem
called recharging time and makes our car the most economical one.

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 INDEX
Sr.No. Chapter Name Page No.
1 Introduction 1-4
1.1 Problem Identification 4
2 Literature Review 5-6
3 Methodology 7-8
3.1 Experimental Setup and Methodology 7
3.2 Objective 8
4 Components Of Self Charging Electrical Car 9-14
4.1 Alternator 9
4.2 Regenerative Braking System 9
4.3 Battery 10
4.4 Inverter and Rectifier 10
4.5 Electric Motor 11
4.6 Power Management System 11
4.7 DC/DC Converter 12
4.8 Mechanical Linkage / Gearbox 12
4.9 Electric Vehicle (EV) Control Unit 12
4.10 Voltage Regulator 13
4.11 Thermal Management System 14
4.12 Control Algorithms and Software 14
5 Capacity & Specification Of Self Charging Electrical Car 15-16
6 Working Principle 17-21
6.1 Energy Generation through the Alternator 17
6.2 Battery Charging via the Alternator 18
6.3 Regenerative Braking to Recover Kinetic Energy 18
6.4 Energy Management via the Power Management System 18
6.5 Powering the Electric Motor 19
6.6 Optimizing Energy Use with Control Algorithms 19
6.7 Voltage Regulation and Thermal Management 19
6.8 Implementation and Testing 20
6.9 Advantages 20
6.10 Disadvantages 21
7 Costing 22
8 Results And Findings 23-25
9 Conclusion 26
Future scope 26
References 27

vi
 LIST OF TABLES
Sr.No Name Of Table Page
No.
1 Costing 22

LIST OF FIGURES
Sr.No Name Of Figure Page
No.
1 Alternator Based Self Charging prototype 2

2 System Layout 7

3 Alternator 9

4 Battery 10

5 Electric motor 11

6 BMS 11

7 Control unit 13

8 Voltage regulator 13

9 System design 15

10 Project model 23

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 Alternator Based Self Charging Electric Car

CHAPTER 1

INTRODUCTION

The history shows the research on electrical vehicles started at 1890s. In this period electric
bicycle got several patents. Ogden Bolten from United States got patent for bicycle battery
with six brush poles, a DC collector and hub motor mounted on the rear wheels in 1895.
Later in 1897 Hosea W Libbey from Boston invented an electric bicycle that was powered by
a double electric motor. Giant Lafree E-Bike brand use same design in 1990. Transportation
is the main sector and every other sector depend on it. But the conventional vehicles which
we used today uses petrol and diesel but which are non-renewable energy resources.
Moreover, these vehicles increase air and noise pollution which is global problem now. This
creates the requirement of clean and renewable energy sources. That‘s why alternating energy
sources getting the attention of the world in last few years. Though electric vehicles has many
drawbacks many research are going on electrical bikes because of its nature friendly
characteristics. Even many nations depend on other countries for petroleum products and
there cost are so high. In order to reduce their dependences on other countries it is necessary
to promote electrical vehicles. Indian government also started many schemes to promote
electrical vehicles. The major factors to use self-recharging electrical vehicles are:

 Reducing the use of fossil fuel

 Fast and flexible
 Nature friendly
 Cut back expenses.

Today we are generating electricity from fossil fuels, they are not environmental friendly. It
causes global warming, therefore we need Non-Conventional sources of energy. A great part
of the oil consumption is recently allocated to the transportation sector and a large portion of
that is used by road vehicles.

According to the international energy overview report, the transportation sector is going to
increase its share in world's total oil consumption by up to 55% by 2030. In order to increase
the energy a revolution in the transportation sector occurs. To reduce use of energy from
fossil fuels in transportation usage and make environment clean and green, we have designed
electric vehicle that uses solar energy and electricity to run. The Photovoltaic cells used to
harness solar energy to generate voltage to charge the battery.

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An Electric Vehicle (EV) can be referred to as an electric drive vehicle, uses one or more
electric motors or traction motors for propulsion. A few electric vehicles will emerge on the
market that it can be powered by a rechargeable battery. The Battery Electric Vehicle (BEV)
is mostly dependent on the battery technology. It provides a level of comfort and ease of
operation that could not be achieved by the gasoline cars of the time. However, in recent
years, increased concerns over the environmental impact of gasoline cars, higher gasoline
prices, improvements in battery technology, and the prospect of peak oil, have brought about
renewed interest in electric vehicle, which are reported to be more environmentally friendly
and cheaper to maintain and run.

Fig 1.1 Alternator Based Self Charging prototype

Electric vehicles are becoming popular and more prevalent due to increased energy costs and
concern regarding the reduction of greenhouse gas emissions. Electric vehicles are powered
by batteries that are contained with the vehicle and usually provide a sufficient charge for the
propulsion of the vehicle through city traffic. The batteries are mounted along with the
vehicle and are used to run the vehicle. In addition to the solar, we can also use alternator to
recharge the batteries. The alternator is connected at the midpoint of the back wheel. The
rotational energy of the wheel can be converted into electrical energy by using generator and
by which supply is fed to the batteries.

In this era conservation of energy is the most necessary part of the society and as automobile
is an important part of society in day to day life, hence the conservation of energy as well as
pollution due to the use of Bio-fuels in automobile sector is a challenging job. So energy
conservation and pollution free vehicle became most important factor.

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To solve this issue the concept of Electric Vehicle (EV) (electricity powered automobile)
system was introduced, this can be used in all type of automobiles such as cars, bus; truck etc.
But once the battery of EV is charged it travels a limited distance, again we have to charge
the battery of vehicle, which is a time consuming process.

If one self charging EV is assembled using some kind of alternators with other circuitries,
which can charge the battery simultaneously when it is moving, then the problem can be
solved. We can use a single powerful battery or two batteries for this case.

The transportation sector is undergoing a significant transformation with the increasing

adoption of electric vehicles (EVs), driven by the need for sustainable and eco-friendly
alternatives to conventional gasoline-powered cars. However, one of the main challenges
facing electric vehicles today is range anxiety, which refers to the fear of running out of
battery power before reaching a charging station. This issue has led to ongoing efforts to
develop more efficient energy solutions that not only reduce charging time but also increase
the driving range of electric vehicles.

One promising solution to this problem is the concept of the Alternator-Based Self-Charging
Electric Car. In this system, an alternator is integrated into the vehicle's design to harness
kinetic energy generated during motion, converting it into electrical energy that can be used
to recharge the vehicle's battery. This concept aims to reduce the dependence on external
charging infrastructure, potentially enhancing the vehicle's range and providing a more
sustainable energy cycle for the car's operation.

The purpose of this project is to explore the feasibility of such a system, focusing on the
design and integration of the alternator with the electric drivetrain of a vehicle. The goal is to
develop a self-charging electric car that can capture and store energy from motion, improving
overall energy efficiency and minimizing the need for external power sources. This
innovative approach seeks to pave the way for future electric vehicles that are not only eco-
friendly but also more independent and self-sustaining in their energy usage.

In this report, we will discuss the working principle, system design, components, advantages,
and challenges associated with the development of an Alternator-Based Self-Charging
Electric Car. We will also explore the potential impact of this technology on the future of
electric mobility, addressing its role in reducing carbon emissions and enhancing the long-
term viability of electric vehicles in everyday use.

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1.1 Problem Identification

In a current scenario, the fossil fuels are depleting rapidly due to the over usage of
conventional vehicles. Generally conventional vehicles use petrol and diesel as a main fuel. It
causes heavy damage to our environment by emitting the harmful gases such as HC
(hydrocarbon), CO (carbon monoxide), and Nox emissions which leads to ozone depletion
and global warming. Also more number of alternative fuels such alcohol (methyl alcohol and
ethyl alcohol), biogas, bio-diesel, natural gas and vegetable such as peanut oil, linseed oil,
rapeseed oil, sunflower oil, etc can be used in order to replace the existing fossil fuel. But a
proper cause and effects has not yet identified. Here the electric vehicle plays a vital role to
boom the automobile to the next generation.

The most of the electric vehicle uses battery as a major source of power. But main problem
we identified is that the battery should be charged for a long period of time in a static
condition only. It leads to consume more conventional power and so it increase the cost of the
electricity used. And also recharging fuel stations are not sufficient as the process of
recharging consumes more time. As the battery is continuously used to run the vehicle, deep
discharge of battery is frequently occurring. So that the life cycle of battery is decreased. Due
to this the replace cost of battery is high.

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CHAPTER 2

LITERATURE SURVEY

Shubham U. Tayde, Neha W. Makode, Umesh M. Laybar, and Prof. Bhushan S. Rakhonde,
discussed about mechanical design of the system and also give better knowledge in system
integration. This paper also helps us to know more about power transmission system which
contain motor, the chain sprockets, flywheel, housing and the rear wheel. We get know how
to do some basic calculation relating to energy transfer through the system and how main
components such as motor and battery will affect by these calculations. M.Sathya Prakash,
provided information about difficulties that faced during the replacement of internal
combustion engine by a battery and electric motor drive in personal transportation electric
vehicles. The paper provides the information regarding principles of alternating current,
direct current, motors, speed controls, batteries, relays and battery. Yogesh jadhav, Gaurav
Kale, Shekhar Manghare, and Sager Patil, provided information regarding Self recharging
electric bike and electric-engine controlled bikes. And also helps us understand the concept of
battery, dynamo as a wind generator, the BLDC engine, controller, charging framework and
sun oriented board. Adithya Kumar, Srirenga Venkatesh, Satheesh Kumar,
Pragatheeshwarar, helped us by giving the information regarding electric power motor and
alternator and how they assist the rider throughout his journey.

The alternator generates electricity which is stored in batteries and these batteries provide
propulsion power for the motor. It also provide information of modification required for
electric bicycle. Robert Cong, Rodney Martinez, Mark Casilang ,Peter Vong, helped us to
know more about the design of E-Bikes and also information regarding lithium-ion battery,
the DC-DC boost converter, the solar panel, the motor, and the motor controller. It will also
possible to improve them further by future students. And also how to make them very
efficient and cost effective. Prof.S.H.Shete, Nitin Patil, Ganesh Khot, Kiran Kokitkar,
Santosh, Vardapgol, Jayashri Sawant, provided the information of controller which takes
PIC16F72 as a core, introduced some important components and Circuit principle diagram.
And also information about controller functions such as over-current protection, under-
voltage protection and so on.

Kannan Shrinivasa Using two auxiliary power sources, Jeyakanthan, Sudharshan (2017)
"Design and Fabrication Of Self-Charging Electric Vehicle" has created a selfcharging
electric vehicle that produces the electricity needed to power it while it is operating. Two

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 Alternator Based Self Charging Electric Car

power sources are used by the car: a horizontal windmill situated in front of it and a dynamo
that is directly connected to the driving motor. A current regulator is used to control the
power source so that the battery can be charged concurrently.

Suhas V, Sukeerth Calastawad, Phaneesh M, and Swaraj S (2015) "Performance Of A

Battery Electric Vehicle With Self Charging Capacity For Its Own Propulsion" In this work,
they designed and built a self charging system for 2 passengers and for weight up to 250 kg.
They created an electric vehicle similar to readily available golf carts on the market. p-ISSN:
2395-0072 whenever it enters a magnetic field; this is the fundamental operation of a DC
motor.

"Constant Electricity Generation From Self Charging Inverter" by Abatan O.A., Adewale
A.O., and Alibi A.A. (2008) focuses on the self charging inverter, a cheap, silent, emission-
free, and uninterrupted alternative source.

"Battery Electric Vehicles Performance, CO2 Emissions, Lifecycle Costs And Advanced
Battery Technology Development" by Daan Bakker (August 2010).

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 Alternator Based Self Charging Electric Car

CHAPTER 3

METHODOLOGY

The standard of this idea is to use an alternator that is related with the shaft of the front
wheels. As the shaft, the alternator is turning that along these lines delivers the electrical
essentialness used for charging the batteries. The battery is related with the motors, which are
presented on back wheels. Right when these vehicle batteries are totally empowered, that can
energize the improvement of the vehicle.

At the same time, the shaft of the turns of the back wheel, this in this manner turns the post of
the alternator. In this manner, the battery begins to charge as the vehicle moves.

Fig 3.1 System Layout

As featured over, the proposed framework is basic, appropriate and financially reasonable.
What should be noted and mulled over is the decision of fitting parts that coordinate the
measure of the vehicle. For model, if the maker chooses to apply this framework on a vehicle
delegated little in weight and measurement, at that point the engines, alternator(s) and the
batteries must be in relative extent and sizes.

3.1 Experimental Setup and Methodology

 To verify the feasibility of the concept, the following experimental setup is suggested:
 Prototype Vehicle: A small electric vehicle or a modified existing electric vehicle will
serve as the test platform.
 Testing of Alternator Integration: The alternator will be connected to the drivetrain of
the vehicle, either through a mechanical coupling or through a generator setup.

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 Monitoring and Data Collection: The performance of the vehicle will be tested on a
controlled track, monitoring parameters such as:
 Energy generated by the alternator
 Battery charge level
 Vehicle speed and range
 Optimization: Using data collected from testing, the system will be optimized for
maximum energy generation and efficient power management.

3.2 Objective

The main objective of this project is to design and develop a prototype of an Alternator-
Based Self-Charging Electric Car, where the alternator generates power to recharge the
vehicle's battery while the car is in motion, thus extending the driving range.

 Design and integration of an alternator system to recharge the car‘s battery.

 Reduction of external charging dependence, contributing to an eco-friendly solution.

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CHAPTER 4

COMPONENTS OF SELF CHARGING ELECTRICAL CAR

The key to building an alternator-based self-charging electric car lies in integrating several
components that allow the vehicle to generate power internally during its operation. Here's a
detailed breakdown of the main components used in this system:

4.1 Alternator (Generator)

Fig 4.1 Alternator

Function: The alternator is the primary component responsible for generating electrical
energy while the vehicle is in motion. It converts mechanical energy from the car‘s wheels
(or engine/motor) into electrical energy in the form of alternating current (AC).

Integration: Typically connected to the vehicle's drivetrain or wheel axles through a belt or
gearing system to harness rotational motion.

Output: AC is produced, which is then converted to DC to charge the battery.

4.2 Regenerative Braking System

Function: Regenerative braking captures the kinetic energy of the vehicle during deceleration
and converts it into electrical energy, which is then used to recharge the battery.

Working: When the driver applies the brakes, the system temporarily reverses the role of the
motor, using the motor to slow the car down and generate electrical power. This power is
then sent back to the battery.

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Benefits: This system helps recover energy that would otherwise be wasted as heat in
conventional braking systems.

4.3 Battery (Energy Storage)

Fig 4.2 Battery

Type: Typically Lithium-Ion (Li-ion) or Lithium Iron Phosphate (LiFePO4) batteries due to
their high energy density and efficiency in charging/discharging cycles.

Function: Stores the electrical energy generated by the alternator and regenerative braking
system. It powers the vehicle's electric motor when required.

Capacity: The size and capacity of the battery will depend on the power requirements and the
driving range of the vehicle.

4.4 Inverter and Rectifier

Function: The alternator generates alternating current (AC), which must be converted into
direct current (DC) to charge the battery. The inverter and rectifier are key components in this
conversion process.

Rectifier: Converts AC to DC.

Inverter: Sometimes used to convert the DC back into AC for the electric motor, if necessary,
for the motor's operation.

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Power Flow Control: Ensures that the energy from the alternator is properly managed and
routed to the battery and motor.

4.5 Electric Motor

Fig 4.3 Electric motor

Function: The primary component responsible for driving the vehicle. It uses the energy
stored in the battery to produce motion (torque) and drive the wheels.

Integration: Can work in tandem with the alternator, particularly in hybrid systems where
both energy from the alternator and battery are used to propel the vehicle.

Types: DC motors or AC motors (induction motors or synchronous motors) are commonly

used in electric vehicles.

4.6 Power Management System (Battery Management System - BMS)

Fig 4.4 BMS

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Function: Monitors and manages the charge and discharge cycles of the battery to optimize
its lifespan and ensure it is not overcharged or undercharged.

Responsibilities:

 Balancing charge between individual cells in the battery.

 Protecting the battery from overheating and overcurrent.
 Optimizing energy flow between the battery, motor, and alternator.

4.7 DC/DC Converter

Function: Converts the voltage from the battery to a level that is appropriate for various
components in the vehicle (like low-voltage systems such as lights, infotainment, etc.).

Importance: Ensures that the energy from the battery is properly distributed to power
auxiliary systems within the vehicle.

4.8 Mechanical Linkage / Gearbox

Function: The mechanical components that link the alternator to the vehicle‘s drivetrain or
wheels to convert rotational motion into electrical energy.

Types:

Belt/Chain System: The alternator can be driven by a belt or chain connected to the car‘s
wheels or engine.

Direct Drive: In some designs, a direct coupling between the alternator and the wheel axles
might be used.

4.9 Electric Vehicle (EV) Control Unit

Function: Manages the operation of the vehicle, including the interaction between the electric
motor, alternator, regenerative braking, and battery system.

Responsibilities:

 Ensures optimal use of the alternator-generated power.

 Manages power distribution from the alternator to the battery or motor.
 Interfaces with the vehicle's systems to ensure seamless operation of the charging and
driving functions.
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 Alternator Based Self Charging Electric Car

Fig 4.5 Control unit

4.10 Voltage Regulator

Fig 4.6 Voltage regulator

Function: Ensures that the voltage produced by the alternator stays within a specified range,
preventing over-voltage or under-voltage situations that could damage the battery or other
components.

Working: Controls the electrical output from the alternator, regulating it before it is sent to
the battery for charging.

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4.11 Thermal Management System

Function: Ensures that the alternator, battery, and other electrical components do not overheat
during operation.

Types:

Cooling Systems: Liquid or air cooling to prevent excessive temperatures in the battery,
alternator, and other sensitive components.

Heat Dissipation: Ensures that heat generated by the alternator and power electronics is
properly dissipated to maintain efficient performance.

4.12 Control Algorithms and Software

Function: The vehicle‘s onboard software uses control algorithms to optimize energy
recovery and charging efficiency.

Responsibilities:

 Managing regenerative braking to maximize energy recovery.

 Regulating the alternator‘s power output based on battery charge levels and vehicle
speed.
 Coordinating between the motor, alternator, and battery to ensure smooth operation
and efficiency.

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CHAPTER 5

CAPACITY & SPECIFICATION OF SELF CHARGING ELECTRICAL CAR

Fig 5.1 System design

Alternator
1. Type: High-efficiency, three-phase alternator with a built-in voltage regulator.
2. Power Rating: 10 kW (adjustable based on vehicle requirements).
3. Efficiency: ≥ 90% (to minimize energy losses).

Battery Management System (BMS)

1. Type: Advanced BMS with cell balancing, overcharge protection, and thermal monitoring.
2. Battery Type: Lithium-ion battery (or other suitable battery chemistry).
3. Capacity: 50 Ah (adjustable based on vehicle requirements).

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Power Electronics
1. Type: High-frequency, high-power DC-DC converter with a built-in controller.
2. Power Rating: 10 kW (adjustable based on vehicle requirements).
3. Efficiency: ≥ 95% (to minimize energy losses).

Electric Motor
1. Type: High-efficiency, three-phase induction motor with a built-in gearbox.
2. Power Rating: 50 kW (adjustable based on vehicle requirements).
3. Efficiency: ≥ 90% (to minimize energy losses).

System Operation
Alternator Operation
1. Speed Range: 1,000 – 5,000 rpm (adjustable based on vehicle requirements).
2. Output Voltage: 48V DC (adjustable based on vehicle requirements).
3. Output Current: 200A (adjustable based on vehicle requirements).

BMS Operation
1. Charging Mode: Constant current-constant voltage (CC-CV) charging.
2. Discharging Mode: Constant power discharging.
3. Cell Balancing: Active cell balancing to ensure optimal battery performance.

Power Electronics Operation

1. Switching Frequency: 10 kHz (adjustable based on vehicle requirements).
2. Duty Cycle: Adjustable based on vehicle requirements.
3. Protection: Overcurrent, overvoltage, and undervoltage protection.

Electric Motor Operation

1. Speed Range: 0 – 100 km/h (adjustable based on vehicle requirements).
2. Torque Range: 0 – 500 Nm (adjustable based on vehicle requirements).
3. Efficiency: ≥ 90% (to minimize energy losses).

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CHAPTER 6

WORKING PRINCIPLE

The core idea behind an alternator-based self-charging electric car is to generate electricity
from within the vehicle itself while it is in motion. This is done through the use of an
alternator, regenerative braking, and other interconnected systems. The primary working
principle of the alternator-based self-charging electric car involves converting kinetic energy
to electrical energy. This can be explained through the following steps:

 Movement of the Vehicle: The vehicle's wheels rotate as the car moves forward. In
traditional electric cars, this energy is typically wasted or used solely to move the
vehicle.
 Mechanical Power Conversion: The alternator is connected to the drivetrain or wheels
of the car. As the car moves, it drives the alternator, causing it to rotate.
 Electricity Generation: The alternator, utilizing electromagnetic induction, converts
the rotational energy into electrical energy (AC power). This is then rectified into DC
power for storage in the battery.
 Power Storage: The generated electricity is fed into the car‘s battery system, allowing
it to recharge the vehicle‘s battery.
 Power Usage: The stored energy is used to power the electric motor, which drives the
vehicle forward.

6.1 Energy Generation through the Alternator

 Alternator Function: The alternator is a key component that generates electricity as

the vehicle moves. It is typically connected to the vehicle‘s drivetrain or wheels,
where it is driven by the motion of the vehicle.
 Mechanical Energy to Electrical Energy: As the car moves, mechanical energy
from the rotating wheels or axles is transmitted to the alternator. The alternator then
converts this mechanical energy into alternating current (AC) using a magnetic field
and a rotor.
 AC to DC Conversion: Since the car‘s battery operates on direct current (DC), a
rectifier is used to convert the AC produced by the alternator into DC, which is
compatible with the battery.

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6.2 Battery Charging via the Alternator

 Storing Energy in the Battery: Once the AC is converted to DC, the energy is routed
to the vehicle‘s battery. The battery stores the electrical energy generated by the
alternator, which is used to power the electric motor that drives the vehicle.
 Continuous Charging: This charging happens continuously as long as the vehicle is
in motion and the alternator is generating power. While this charging method isn‘t
sufficient to fully power the car for long distances on its own, it slows the depletion of
the battery and provides supplementary energy during driving.

6.3 Regenerative Braking to Recover Kinetic Energy

 Regenerative Braking System: When the driver applies the brakes, the vehicle's
electric motor temporarily switches roles and acts as a generator. Instead of
consuming energy from the battery to drive the car, the motor captures kinetic energy
from the vehicle's deceleration and converts it into electrical energy.
 Energy Recovery: The converted electrical energy is then sent to the battery, which
helps recharge it. This energy recovery can be particularly useful in urban driving,
where frequent stopping and starting occur.
 Battery Charging: During braking, energy is sent directly to the battery. This process
helps recover up to 30-40% of the energy lost in traditional braking systems, further
reducing the need for external charging.

6.4 Energy Management via the Power Management System (BMS)

 Battery Management System (BMS): The BMS monitors the battery's state of
charge, temperature, and health to ensure optimal charging and discharging cycles. It
makes sure that the battery isn't overcharged or undercharged and that the alternator
and regenerative braking system are working efficiently.
 Power Flow Control: The power management system coordinates between the
energy coming from the alternator, regenerative braking, and the battery, ensuring
smooth power flow to the electric motor as needed.

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6.5 Powering the Electric Motor

 Electric Motor Function: The electric motor is responsible for driving the wheels of
the car. It uses the energy stored in the battery to generate the rotational force required
to propel the car forward.
 Battery Discharge: When the vehicle needs to accelerate or maintain speed, the
stored energy in the battery is used to power the motor. The motor uses the DC power
stored in the battery to drive the vehicle's wheels, providing a smooth and efficient
ride.

6.6 Optimizing Energy Use with Control Algorithms

 Control Algorithms: The car‘s onboard control unit uses advanced algorithms to
manage energy usage efficiently. It determines when to rely on the alternator,
regenerative braking, and battery to optimize driving range and energy recovery.
 Alternator Activation: The alternator is actively used when the car is in motion and
when the vehicle‘s speed is high enough to generate useful energy for the battery.
 Braking Energy Recovery: The regenerative braking system is used to recover
energy during deceleration and to recharge the battery. It helps minimize energy loss
while stopping.
 Battery Discharge Management: The system decides when the battery should
supply power to the motor, ensuring that it doesn‘t deplete too quickly and that the
energy from the alternator or regenerative braking can offset the battery usage.

6.7 Voltage Regulation and Thermal Management

 Voltage Regulation: The alternator produces alternating current (AC) that needs to
be regulated to maintain a consistent voltage for the battery. A voltage regulator
ensures that the output voltage is safe for the battery and doesn't exceed safe limits.
 Thermal Management: The alternator, motor, and battery generate heat while
operating. The thermal management system ensures that these components don‘t
overheat, protecting them from damage and ensuring the system operates efficiently
over time.

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6.8 Implementation and Testing

Prototype Development: The first step involves creating a prototype vehicle with an
integrated alternator and regenerative braking system. The alternator is mounted and
connected to the vehicle‘s wheels or motors.

System Integration and Calibration: After installation, the system is calibrated to ensure
optimal charging rates and performance, with the vehicle‘s energy management system
optimized to manage power flow from the alternator.

Testing: A series of tests are conducted to assess the power generation efficiency of the
alternator, the effectiveness of the regenerative braking system, and the overall performance
of the vehicle. Key metrics such as battery charge rate, power consumption, and energy
recovery efficiency are measured.

6.9 Advantages

There are several advantages to a self-charging vehicle system utilizing a 12V generator
attached to the wheels of vehicles and a 12V, 5Ah battery:

 Sustainable Energy Generation: By harnessing the rotational energy of the vehicle's

wheels, the generator can produce electricity without relying on external power
sources. This sustainable energy generation reduces the vehicle's dependence on fossil
fuels and contributes to a greener transportation solution.
 Continuous Power Generation: The generator operates whenever the vehicle is in
motion, providing a continuous source of power to charge the battery. This ensures
that the battery remains charged or maintains a high level of charge, allowing for
uninterrupted operation of the vehicle's electrical systems.
 Extended Driving Range: With a self-charging system in place, the vehicle can
potentially extend its driving range without the need for frequent recharging stops.
This is especially advantageous for electric vehicles (EVs) or hybrid vehicles, which
may otherwise be limited by battery range.
 Increased Efficiency: By capturing and converting kinetic energy into electrical
energy, the self-charging system improves the overall efficiency of the vehicle. It
maximizes the use of available energy resources and minimizes energy wastage
during vehicle operation.

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 Reduced Environmental Impact: Self-charging vehicles produce fewer emissions and

pollutants compared to traditional combustion engine vehicles. By promoting cleaner
energy generation and consumption, these vehicles contribute to lower air pollution
levels and mitigate climate change impacts.
 Lower Operating Costs: With the ability to generate electricity on-the-go, self-
charging vehicles can reduce the need for external charging infrastructure and
associated costs. This can lead to lower operating expenses for vehicle owners and
operators over the vehicle's lifetime.
 Enhanced Reliability: The self-charging system provides a redundant power source
for the vehicle's electrical systems, enhancing overall reliability and resilience. In case
of battery depletion or failure, the generator can continue to supply power, ensuring
uninterrupted operation of critical vehicle functions.

6.10 Disadvantages

1. Energy Efficiency: The amount of energy generated by the alternator may not be
sufficient to fully charge the battery, meaning external charging may still be required.
2. Mechanical Losses: The alternator will consume some of the mechanical energy that
would otherwise be used to propel the car, reducing overall efficiency.
3. Complexity in Integration: Integrating the alternator with the vehicle's powertrain and
battery management system may require sophisticated engineering.

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CHAPTER 7

COSTING

Procurement of items required for the project is done by manufacturing components and
purchasing some components. Cost increased during manufacturing of the components
depends upon raw material cost and processing cost.

SR NO MATERIAL QUANTITY AMOUNT

1 Motor 2 600/-

2 Alternator 2 550/-

3 Motor And Alternator Driver 1 600/-

4 Lithium Ion Battery 1 1200/-

5 Led Light 4 100/-

6 Motor Wheel 4 550/-

7 Pvc Pipe 1 350/-

8 Box 1 350/-

9 Electric Components ----- 2000/-

10 Other ------ 3700/-

Total 10,000/-

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CHAPTER 8

RESULTS AND FINDINGS

Fig 8.1 Project model

 The tests show that the alternator generates a small amount of energy during normal
driving, which can help slow the rate of battery depletion.
 Regenerative braking provides significant energy recovery during deceleration,
enhancing the overall efficiency of the system.
 The battery life is extended because of the additional charging provided by the
alternator and braking system.

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CHAPTER 9

CONCLUSION

The self-charging electric car was fabricated. This car is very feasible for day-to-day travel
similar to motorbike. The car is much comfortable which supports the driver for easy riding.
It is very less weight compared to a small car and provides better safety than a two-wheeler.
This project provides flexibility in operation and noiseless operation. The scope of this
project lies in fully determining and understanding the functioning of car. This project gives
solution to the old problems, where the most common problem arising from existing electric
car is the recharging system. The conventional system leads to consume more conventional
power and time. Hence our project reduces the problem called recharging time and makes our
car the most economical one.

We can further develop more features in this car. This car was fabricated for the purpose of
self charging the battery when the vehicle is in moving condition. This vehicle uses a Lead
acid battery which needs replacement after some period. Instead of using Lead acid battery,
we can switch over to Lithium-ion batteries which provides more life cycles and they are
much reliable. We can use high rated DC motor to drive the high loads as possible.

New inventions of lighter but stronger materials like carbon fibers, High strength polymers
can help in reducing the overall weight of the car and thus smaller sized high efficiency otors
can be used. In future, we can add solar panels to this car to make it more economical. We
can encrypt the idea of multipurpose vehicle similar to existing, so that we can develop the
electric car to the next level.

Future Scope

While the concept of a self-charging electric car is promising, further research and
development is required to make it more efficient and practical for mass production. Future
advancements could include:

 Improved Alternator Designs: More compact, lightweight, and efficient alternators.

 Regenerative Braking Systems: Integrating regenerative braking to further enhance
energy recovery.
 Energy Harvesting Technology: Exploring additional methods to capture energy, such
as solar panels integrated into the car‘s body.

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REFERENCE

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