CHAPTER ONE

INTRODUCTION
1.1BACKGROUND OF STUDY
Nigeria, a nation with rapid population growth and increasing industrial activity, faces significant
challenges in ensuring a stable and accessible energy supply. The national power grid is often strained,
leading to frequent outages and a reliance on expensive and environmentally unfriendly fossil fuel
generators for many households and businesses. This energy deficit hinders economic growth, impacts
daily life, and contributes to environmental pollution.
In the pursuit of sustainable and reliable energy alternatives, mechanical energy storage systems,
particularly flywheel energy storage, have garnered renewed interest globally. Flywheels offer a clean and
efficient method for storing kinetic energy, which can then be converted into electrical energy on demand.
Unlike other sources such as batteries and fossil fuel, flywheels boast a long lifespan, high power density,
and are environmentally benign.
Historically, flywheels have been utilized in various mechanical systems for energy regulation and power
smoothing. Modern advancements in materials science and engineering have paved the way for the
development of high-speed flywheels capable of storing significant amounts of energy. These systems are
being explored for applications ranging from grid stabilization and electric vehicles to portable power
solutions.
Building upon the principles of mechanical energy storage, this project explores the integration of a
spring mechanism with a flywheel to create a novel electricity generation system. The concept involves
using the potential energy stored in a spring to initiate and sustain the rotation of a flywheel, which in turn
drives a generator to produce electricity. This approach has the potential to offer a compact, off-grid
power solution, particularly suitable for smaller-scale applications where access to the national grid is
unreliable or non-existent. Furthermore, a spring-driven system could reduce the reliance on continuous
external power sources for charging, offering a degree of energy autonomy.
1.2 STATEMENT OF THE PROBLEM
The current state of Nigeria’s electricity sector has shown that it is not sustainable for the current
population and more so a rapidly growing one. Existing alternatives such as fossil fuel are
i. Expensive to afford and
ii. Require regular maintenance.
iii. Have shorter lifespan.
iv. Environmental impact.
Other renewable energy such as solar and wind energy are intermittent and unreliable
Therefore, the core problem this study seeks to address is the need for a sustainable, relatively low-
maintenance, and potentially cost-effective small-scale power generation solution that can mitigate the
challenges of unreliable grid supply and the drawbacks of traditional alternatives within the Nigerian
context.
1.3 PURPOSE OF THE STUDY
The purpose of this study is to design, construct, and evaluate the performance of an integrated return
spring flywheel driven fuel-less generator as a potential small-scale power solution relevant to the energy
challenges faced in Nigeria.

1.4 SIGNIFICANCE OF THE STUDY

 This research holds significant potential for contributing to the discourse on alternative energy
solutions and addressing specific energy challenges prevalent in Nigeria. The findings of this
study could be significant in the following ways:
 Demonstrating a Novel Approach to Small-Scale Power Generation: This project explores a
unique integration of spring and flywheel mechanisms for electricity generation, potentially
offering a distinct alternative to conventional small-scale generators and energy storage systems.
The successful demonstration of such a system could inspire further innovation in mechanical
energy conversion.
 Potential for Off-Grid and Backup Power Solutions in Nigeria: Given the persistent issues with
the national grid, a functional spring flywheel generator could offer a viable off-grid power
source for households, small businesses, and critical facilities (e.g., clinics, schools) in areas with
limited or no access to the grid. It could also serve as a reliable backup power solution during grid
outages in more connected areas, reducing reliance on polluting and costly fossil fuel generators.
 Potential for Local Manufacturing and Economic Empowerment: Depending on the materials and
manufacturing processes involved, the design of a spring flywheel generator could potentially be
adapted for local production in Nigeria. This could create opportunities for skill development, job
creation, and economic empowerment within local communities.
 Providing Insights into Mechanical Energy Storage and Conversion: This research will contribute
valuable data and insights into the efficiency and practical application of mechanical energy
storage and conversion using a spring-flywheel system. The findings could inform future research
and development in this area, both in Nigeria and globally.
 Contribution to Sustainable Energy Development: By exploring a power generation method that
does not rely on fossil fuels during operation, this study aligns with the global and national
agenda for promoting sustainable energy sources and reducing carbon emissions. A successful
spring flywheel system could represent a cleaner alternative for specific power needs.
1.5 ENERGY SOURCES
Flywheel-spring based energy storage systems are hybrid mechanical energy storage solutions that
combine the high-speed rotational energy storage of a flywheel with the elastic potential energy storage of
a spring. These systems are designed to improve energy storage efficiency, power density, and response
time compared to standalone flywheel or spring-based systems. The energy sources for such systems can
vary, depending on the application and design requirements.

Primary Energy Sources

The energy input to a flywheel-spring system can come from multiple sources, including:

1. Electrical Energy (Electromechanical Conversion)

- Electric Motors/Generators: The most common method involves using an electric motor to accelerate
the flywheel, converting electrical energy into kinetic energy. When energy is needed, the flywheel’s
rotation drives a generator to produce electricity.
- Regenerative Braking: In automotive and rail applications, kinetic energy from deceleration is captured
and used to spin the flywheel, which can later be converted back into electricity or mechanical power.

2. Mechanical Energy (Direct Input)

- Human Power: In small-scale applications (e.g., hand-cranked devices), mechanical energy from human
motion can wind a spring and spin a flywheel.
- Wind and Water Turbines: Renewable energy sources like wind or hydropower can directly drive the
flywheel-spring system, storing energy mechanically before converting it to electricity as needed.
- Industrial Machinery: Excess mechanical energy from rotating equipment (e.g., conveyor belts, pumps)
can be stored in the flywheel-spring system for later use.

3. Renewable Energy Sources (Indirect Input)

- Solar Power: Photovoltaic (PV) systems can supply electricity to a motor that spins the flywheel, storing
energy for use during low sunlight periods.
- Tidal/Wave Energy: The intermittent nature of ocean energy can be smoothed out by storing mechanical
energy in a flywheel-spring system.
4. Combustion Engines (Hybrid Systems)
- Internal Combustion Engines (ICE): In hybrid vehicles or backup power systems, an engine can drive
the flywheel to store energy, which is later released to assist in acceleration or power generation.
- Gas Turbines: In aerospace and industrial applications, excess energy from turbines can be stored in a
flywheel-spring system for peak power demands.
- Sustainable Energy
Sustainable energy refers to energy sources that are renewable, environmentally friendly, and capable of
meeting current demands without compromising future generations. These energy sources produce
minimal greenhouse gas emissions and reduce dependence on finite fossil fuels. The shift toward
sustainable energy is crucial for combating climate change, ensuring energy security, and promoting
economic stability.

Types of Sustainable Energy

1. Solar Energy
- Harnessed using photovoltaic (PV) panels or solar thermal systems.
- Clean, abundant, and scalable for residential and industrial use.
- Reduces reliance on fossil fuels and lowers electricity costs over time.

2. Wind Energy
- Generated using wind turbines that convert kinetic energy into electricity.
- Highly efficient in windy regions, both onshore and offshore.
- Produces zero emissions during operation.

3. Hydropower
- Uses flowing or falling water to generate electricity via dams or run-of-the-river systems.
- One of the oldest and most reliable renewable energy sources.
- Can provide large-scale energy storage through pumped hydro storage.

4. Biomass Energy
- Derived from organic materials like wood, agricultural waste, and biofuels.
- Can be carbon-neutral if sustainably managed.
- Used for heating, electricity, and transportation fuels.
5. Geothermal Energy
- Extracts heat from the Earth’s core to generate electricity or provide heating.
- Highly efficient in geologically active regions.
- Low emissions and consistent energy supply.

6. Tidal and Wave Energy

- Uses ocean currents and waves to produce electricity.
- Predictable and reliable compared to wind and solar.
- Still in early development but holds great potential.

Benefits of Sustainable Energy

- Reduces carbon emissions and mitigates climate change.
- Enhances energy security by reducing dependence on imported fuels.
- Creates jobs in renewable energy industries.
- Lowers long-term energy costs as technology advances.
- Challenges:
- High initial investment for infrastructure.
- Intermittency issues (solar and wind require storage solutions).
- Land use concerns (large solar/wind farms may impact ecosystems).
Sustainable energy is essential for a cleaner, more resilient future. Continued advancements in
technology, policy support, and public awareness will accelerate the transition to a renewable energy-
based economy.

- Non-Sustainable Energy
Non-sustainable energy comes from finite resources that cannot be replenished within a human lifetime.
These sources, primarily fossil fuels, have powered industrialization but contribute significantly to
environmental degradation, climate change, and geopolitical conflicts. As reserves deplete, the need for
alternative energy becomes urgent.
- Types of Non-Sustainable Energy:
1. Coal
- Mined from the earth and burned for electricity and heat.
 - Highly polluting, releasing CO₂, sulfur dioxide, and particulate matter.
- Declining in use due to environmental regulations.

2. Oil (Petroleum)
- Extracted via drilling and refined into gasoline, diesel, and plastics.
- Major contributor to air pollution and greenhouse gases.
- Subject to price volatility and geopolitical tensions.

3. Natural Gas
- Composed mainly of methane, used for heating, electricity, and industry.
- Cleaner than coal and oil but still emits CO₂ when burned.
- Leakage of methane (a potent greenhouse gas) is a major concern.

4. Nuclear Energy (Fission-Based)

- While low in carbon emissions, uranium is a finite resource.
- Produces radioactive waste with long-term storage challenges.
- Risks of accidents (e.g., Chernobyl).

1.7 PRINCIPLE OF FLYWHEEL-SPRING BASED ENERGY STORAGE

A flywheel-spring based energy storage system is a hybrid mechanical storage solution that combines the
high-speed rotational energy storage of a flywheel with the elastic potential energy storage of a spring.
This system leverages the advantages of both components to achieve efficient energy storage, rapid
response times, and improved power density. The principle of operation relies on converting input energy
into kinetic energy (flywheel) and elastic potential energy (spring), which can be discharged as needed.

1.8 SCOPE OF THE STUDY

The scope of this study is specifically limited to the following:
 Design Parameters: The design will consider readily available materials and fabrication
techniques accessible within Nigeria. Complex or highly specialized materials and manufacturing
processes that are not easily accessible locally will be used in this initial prototype.
 Construction of a Single Prototype: The study will involve the construction of one functional
prototype of the integrated generator system. Mass production or the development of multiple
variations of the design are beyond the scope of this initial research.
 Performance Evaluation: The performance evaluation will primarily focus on measuring key
electrical output characteristics (voltage), and a preliminary assessment of the system's efficiency.
Long-term durability testing and extensive optimization of the design are not within the scope of
this initial study.
 Type of Generator: The study will utilize a commercially available small-scale AC generator that
is compatible with the expected rotational speed and torque output of the flywheel system. The
design and construction of a custom-built generator are excluded from this scope.
 Spring Mechanism: The research will focus on the use of tension spring chosen based on
availability and suitability for the energy storage and release requirements. A comparative
analysis of different spring types is not within the scope.
 Load Testing: Performance evaluation will involve testing the generator with a limited range of
resistive loads to assess its power output capabilities under different conditions. Extensive testing
with various complex or dynamic loads is beyond the current scope.
 Economic and Environmental Analysis: While the significance of the study touches upon the
potential for sustainability and cost-effectiveness, a detailed economic feasibility analysis or a
comprehensive environmental impact assessment is not included within the scope of this initial
research.
 Geographical Focus: The study is conducted within Bauchi state, and the availability of materials
and local manufacturing capabilities will be a significant consideration in the design and
construction phases.
 CHAPTER TWO

2.1 Literature Review

This project portrays that Flywheel and Spring Power systems are turning into promising energy storage
technology, offering advantages like high efficiency, long lifetime, and fast response times. The literature
review reveals that this project primarily involves storing kinetic energy in a rapidly rotating flywheel,
which can then be converted back into electrical energy when needed. Key components include the
flywheel itself, springs, battery, an electrical machine (motor/generator), power electronics converters, a
control system, and bearings.

Key Features and Advantages:

High Power Density and Efficiency: Flywheel and spring systems can deliver high power quickly and
efficiently.
Long Lifespan and Low Maintenance: They have a long operational life and require minimal
maintenance, especially when using magnetic bearings.
Fast Response Time: These systems can quickly respond to changes in demand, making them suitable for
applications requiring rapid power delivery.
Scalability: Flywheels can be configured in banks to store large amounts of energy.
Environmental Friendliness: Flywheel and spring systems have a low environmental impact compared to
some other energy storage technologies. Hence, Flywheel Energy Storage Systems (FESS) have gained
global recognition as an efficient energy storage solution due to their fast response times, high efficiency,
and long lifespan. In Nigeria, where unreliable power supply and frequent grid instability are major
challenges, FESS presents a viable alternative to conventional battery storage systems. This chapter
reviews existing literature on FESS, focusing on its relevance, potential applications, and feasibility in
Nigeria’s energy landscape.
2.2 Historical Development and Global Adoption of Flywheel Energy Storage
The concept of flywheels dates back centuries, but modern flywheel energy storage emerged with
advancements in materials, magnetic bearings, and power electronics (Genta, 1985). Developed countries
have adopted Flywheel Energy storage for grid stabilization, renewable energy integration, and critical
backup power (Hebner et al., 2002).
In Nigeria, energy storage solutions are still largely dependent on lead-acid batteries and diesel
generators, which have high maintenance costs and environmental concerns (Ogunmodimu & Okoroigwe,
2019). The integration of Flywheel Energy storage could provide a more sustainable and efficient
alternative, especially given Nigeria’s growing renewable energy sector (solar and wind) which requires
reliable storage solutions.
2.3 Fundamental Principles of Flywheel Energy Storage
A flywheel stores energy as rotational kinetic energy, expressed by:
E = ½ Iw²
Where:
- ( E ) = stored energy (Joules),
- ( I ) = moment of inertia (kg·m²),
- ( W ) = angular velocity (rad/s).

2.4 Key Components of a Flywheel Energy Storage System

Flywheel :
The core component, storing kinetic energy. Materials like steel and composites are used, with composite
materials generally allowing for higher speeds and energy densities. Stores rotational energy to maintain
momentum.
- Design Considerations:
- High moment of inertia for prolonged energy retention.
- Balanced construction to minimize vibrations.

Electrical Machine (Generator):

Converts electrical energy to mechanical energy. Alternator (220V, 50Hz Single-Phase)
Function: Converts mechanical energy into electrical power.
- Rotor: Electromagnet or permanent magnet generating a magnetic field.
- Stator: Windings where AC voltage is induced.
- Voltage Regulator: Maintains stable 220V output under varying loads.
Synchronous motor:
Maintains flywheel speed & compensates for losses. Electric Starter Motor (48V, 2kW)

Function: Accelerates the flywheel to 1500 RPM before disengaging.

- Type: Brushless DC (BLDC) or Permanent Magnet Synchronous Motor (PMSM).

- Stator: Electromagnetic coils that generate a rotating field.

- Rotor: Permanent magnets that align with the stator field.

- Motor Controller: Regulates speed and torque using PID controller.

2.5 CASE STUDY:

Article 1: Design and Fabrication of a Fuel-less Generator Source: Academia.edu, Published November
16, 2023Summary: This article explores the design and fabrication of a fueless generator utilizing a
Flywheel Energy Storage System (FESS). The system comprises a flywheel coupled with a DC motor and
alternator, powered by a battery, to store and convert mechanical energy into electrical energy. The study
emphasizes the system’s high power density (983.4 kW/kg) and its ability to produce 3.5 kW of
electricity, though it notes a low energy density (3.71 kWh/kg), which limits sustainability. The generator
achieved an efficiency of 75.9%, with recommendations for improving energy density to enhance long-
term performance. Methodology: The researchers constructed a prototype using a flywheel, DC motor,
alternator, and battery. Performance was evaluated through tests measuring power output, efficiency, and
battery discharge rates under various load conditions. The study also reviewed the system’s components,
such as electric machines, power electronics, and bearing systems, to assess their impact on efficiency.
Findings: The FESS-based generator is effective for applications like uninterruptible power supply (UPS)
and regenerative braking due to its high cycle life, low environmental impact, and ability to store
megajoule-level energy. However, windage losses in high-speed rotating components reduce efficiency,
and the system requires improvements in energy density for sustained operation. Relevance to Project:
This article is highly relevant as it directly addresses a fueless generator using FESS, which could align
with your project’s focus on sustainable energy solutions. The emphasis on improving energy density
provides a potential research direction for your work.
Article 2: Fuelless Power Generating Set and Power Inverter System: Analysis of Load and Efficiency
Appraisal Source: ResearchGate, Published October 22, 2024Summary: This study compares the
performance of a fueless generator and a power inverter, both designed and constructed at the Federal
College of Agriculture, Nigeria. The fueless generator uses a 12V/100Ah battery to drive a 1 kW DC
motor, which powers an 800VA alternator. The research evaluates load performance and efficiency,
highlighting the generator’s environmental benefits and its operation without fossil fuels. Methodology:
The generator was constructed using a DC motor, alternator, battery, diode for recharging, and a voltage
regulator. Performance tests measured efficiency across different loads, ranging from 100W to 600W.
The study used mathematical models to analyze energy conversion and load handling. Findings: The
generator achieved a peak efficiency of 97.4% at 100W load but dropped to 71.7% at 600W, indicating
reduced efficiency with higher loads. The incorporation of a diode for battery recharging and a controller
for voltage regulation improved performance, but the system struggled with high-load sustainability due
to battery discharge rates. Relevance to Project: This article provides practical insights into constructing a
fueless generator with readily available components, which could guide your project’s design phase. The
efficiency analysis under varying loads is valuable for optimizing your generator’s performance.
Article 3: Fuel less Generator: Review Source: Europub, Published Unknown DateSummary: This review
article discusses the concept of fueless generators as an alternative to traditional fossil fuel-based power
generation. It highlights the environmental drawbacks of burning fuels (e.g., coal, diesel) and proposes
fueless generators as a sustainable solution that operates without wired power sources. The article also
touches on phase change materials (PCMs) for thermal conductivity enhancement, though this is less
central to the fueless generator focus. Methodology: The study reviews existing literature on fueless
generators, focusing on their operational principles and components, such as DC motors, alternators, and
batteries. It includes a brief discussion on thermal management using PCMs in cylindrical annulus
configurations to improve energy storage efficiency. Findings: Fueless generators are presented as
environmentally friendly, noiseless, and capable of generating power without fossil fuels. The review
notes their potential to power various applications, but it lacks detailed empirical data or performance
metrics, focusing instead on conceptual advantages and material considerations. Relevance to Project:
While less detailed than the other articles, this review provides a broad context for fueless generators,
emphasizing their environmental benefits. It can help frame your project’s motivation and highlight the
need for sustainable energy solutions, though you may need to supplement it with more technical data
from other sources.
Conclusion These articles collectively underscore the potential of fueless generators as sustainable,
environmentally friendly alternatives to fossil fuel-based power generation. The first article provides a
detailed look at FESS-based systems, offering technical insights into power density and efficiency
challenges. The second article offers practical construction and performance data, useful for your
project’s design and optimization. The third article contextualizes the need for fueless generators, though
it lacks depth in technical analysis. For your project, consider focusing on improving energy density (as
suggested in Article 1) and optimizing efficiency across load conditions (as explored in Article 2) to
enhance the practicality of your fueless generator.
NASA’s 2018 flywheel system for satellite power buffering (15 kJ/kg efficiency).
Serve as support to the flywheel. Magnetic bearings are favored for their low friction and long lifespan,
while mechanical bearings are often used as backups.

Formula 1’s Kinetic Energy Recovery System (KERS) using springs for rapid energy discharge.
Formula 1’s Kinetic Energy Recovery System (KERS) was an early hybrid technology introduced to
improve energy efficiency and add a performance boost to the cars. While most KERS implementations
used electrical systems (batteries and motor-generators), some experimental designs explored mechanical
KERS, including spring-based systems for rapid energy discharge.
 MIT (2021): 30% reduction in battery stress using flywheel buffering. In 2021, researchers at MIT
(Massachusetts Institute of Technology) developed an innovative flywheel-based energy buffering system
that reduced battery stress by up to 30% in hybrid and electric vehicles (EVs). This approach aimed to
improve battery lifespan and efficiency by offloading rapid charge/discharge cycles to a mechanical
flywheel.
Mechanical Design of Flywheels for Energy Storage: A Review (Dragoni, 2019) Content: Surveys
mechanical rotor design, composite materials, magnetic bearings, and integration with brushless DC and
permanent magnet motors/generators . Challenges: Managing heat, eddy-current losses, structural
stresses, and optimizing motor/generator design for efficiency and reliability.

A Review of Flywheel Energy Storage System Technologies and Their Applications (MDPI, 2017)

Content: Covers power electronics dual-drive converters (DC⇌AC, AC↔AC matrix), multilevel
inverters, and control topologies for smooth motor–grid interfacing .

Challenges: High switching losses in converters, harmonic distortion, DC-link stability, thermal load, and
switching-frequency trade-offs.

An Overview of the R&D of Flywheel Energy Storage Technologies in China (MDPI, 2023) details
widespread use of permanent magnet motors (PMSM), coreless BLDC, induction, and homopolar
alternators in FESS systems. Reports PMM systems from 2016–2023. Challenges: Rotor heat dissipation
—especially in vacuum-sealed, high-speed systems and PMM designs; need for cooling shaft cavities and
thermal modeling.

2.6 OVERVIEW

Startup Phase
1. The microcontroller activates the starter motor via a relay.
2. The motor accelerates the flywheel to 1500 RPM.
3. Once the target speed is reached, the motor disengages.

Energy Sustainment Phase

1. The flywheel maintains rotational inertia, reducing dependency on the motor.
2. Torsional springs assist in torque amplification, ensuring smooth power transfer.
3. The alternator converts mechanical energy into 220V AC.

Shutdown Phase
1. The PID controller reduces alternator load gradually.
2. The flywheel decelerates safely (with regenerative braking if applicable).
3. The system powers down, ready for the next cycle.
 Starter Motor Control Circuit
- Microcontroller triggers a relay via a transistor (TIP120).
- Flyback diode prevents voltage spikes from damaging the relay.
- Fuse protection ensures safety against overcurrent.

Alternator Output Regulation

- Voltage regulator maintains 220V, 50Hz output.
- PID feedback loop adjusts load dynamically to stabilize RPM.

Battery Management
- Battery management system ensures safe charging/discharging of the LiFePO4 battery.
- Low-voltage cutoff prevents deep discharge.

2.7 RESEARCH GAPS

Flywheel energy storage systems (FESS) have gained attention as a sustainable alternative to
conventional batteries and fossil fuel generators. This review examines existing research on
flywheel-based generators, torsional spring mechanisms, and control systems to identify gaps
addressed by this project—a 55kVA fuel-less generator combining a flywheel, springs, and a
PID-controlled alternator.

1. Flywheel Energy Storage Systems

Flywheels store kinetic energy via rotational motion and have been studied for decades (Genta,
1985). Key findings include:
- Materials: Steel flywheels are cost-effective but heavy, while carbon fiber offers higher energy
density (Arani et al., 2017).
- Bearing Systems: Magnetic bearings reduce friction losses but increase complexity (Sapinski,
2011).
- Efficiency: Modern FESS achieve 85–95% efficiency but require high RPM (Pullen, 2020).

Gap: Most studies focus on grid-scale FESS, neglecting small-scale, self-sustaining designs like
this project.
2. Torsional Springs in Energy Transfer
Torsional springs assist in torque amplification and smoothing power delivery. Research shows:
- Energy Recovery: Springs can recover **10–15% of deceleration energy (Hafidi et al., 2018).
- Fatigue Life: Repeated loading causes spring wear, requiring durable materials (Budynas &
Nisbett, 2015).

Gap: No studies combine flywheels and springs for off-grid power generation, leaving optimal
stiffness and durability unverified.
3. Control Systems for Flywheel Generators
PID controllers regulate speed in energy systems (Åström & Hägglund, 2006). Relevant work
includes:
- Motor Control: BLDC motors with PWM-based drivers improve efficiency (Krishnan, 2017).
- Load Management: PID loops stabilize alternator output under variable loads (Ogata, 2010).

Gap: Prior work assumes grid-tied systems; standalone PID tuning for fuel-less generators is
unexplored.

Existing literature covers flywheels, springs, and control systems independently, but not their
integration into a self-sustaining fuel-less generator. This project bridges the gap by:
1. Testing flywheel-spring synergy for torque assistance.
2. Developing a PID control system for standalone operation.
3. Evaluating cost vs. efficiency for small-scale applications.

Future Work: Prototype testing will validate these concepts empirically