CE 3.1: Project on Design and Fabrication of Electro Magnetic Engine

This project report details the design and fabrication of an electromagnetic engine, undertaken to reduce fuel consumption and promote eco-friendliness. The project involved designing and constructing an engine that utilizes electromagnetic force instead of fuel-based combustion, aiming to replicate the benefits of a 2-stroke engine while eliminating its disadvantages. The report outlines the project's objectives, including enhancing efficiency, evaluating power output, and minimizing environmental impact. It describes the author's role as the chief mechanical engineer, detailing the activities, skills applied, and challenges encountered, such as power management issues. The report also includes the methodologies used, the selection of materials, the fabrication process, and comparisons between theoretical and experimental values. The project successfully addressed technical difficulties and proposed innovative solutions. The report concludes with an overview of the project's contributions, including the development of a fuel-free engine design and the documentation of project progress.

CE 3.1 Information of the Project
Project Name: Design and Fabrication of Electro Magnetic Engine
Location of the project: Please fill
Project Duration: Please fill
Organization’s Name: Please fill
Role and Designation in the project: Chief Mechanical Engineer
CE 3.2 Background of the Project
CE 3.2.1 Basic Characteristics of the Project
Electro magnetic actuator is one of the most significant system that converts electrical
energy into reciprocation of motion with successful utilization of electro magnetic effect. A
successful utilization of internal combustion engine has been highly predominant for longer
time. However, for automotive purposes it utilizes petrol or diesel to provide the required
energy. In this project, my aim was to eradicate the disadvantages, related to the conventional
2 stroke engine, only after keeping the advantages perfect like power stroke in every
revolution, compact design and lightness. The air and charge was being inducted into crank
case with the help of a spring loaded inlet valve, as soon as the pressure gets reduced for
upward piston motion in compression stroke. I have achieved this after changing the power
structure from the fuel pressure to electro magnetic force. I had to propose a compact design
for the electric operated engine, so that use of fuels is eradicated successfully. Therefore, I
had to design as well as fabricate an electro magnetic engine, which consume zero fuel and is
extremely eco friendly and cost effective in nature.

CE 3.2.2 Developed Objectives for this project
The project work of Design and Fabrication of Electro Magnetic Engine was being
completed with the major purpose of designing as well as fabricating the electro magnetic
engine to reduce fuel consumption. I had to ensure that this particular project is not providing
any type of erroneous outcome and is being successfully executed with higher efficacy as
well as efficiency. Therefore, to obtain suitable and appropriate results from this project, I
had to develop few of the most distinctive objectives:
 To effectively design and fabricate an electro magnetic engine to make the system
much more efficient.
 To evaluate the engine for its power output and efficiency.
 To eradicate the excessive utilization of fuel consumption and hence making the
entire machine quite eco friendly and cost effective.
 To save up non renewable energy of fuel for betterment of the environment.
 To eradicate the disadvantages associated with the conventional 2 stroke engine only
after keeping the expected benefits intact.
 To ensure that this particular work is getting executed in given time period and even
estimated the resources and budgets and not even compromising as per the quality of
the entire work.
 To properly compare the obtained results in the experiment with my desired project
result.
CE 3.2.3 My working areas in this work
I, being one of the most responsible mechanical engineer, was hired as the main
mechanical engineer within this particular project of Design and Fabrication of Electro
Magnetic Engine by my respective project leader as well as engineering department manager.
As I had always been a main member of various popular mechanical and metallurgical

Engineering Department
Manager
Project Leader
Chief Mechanical Engineer (Me)
Team Member of the project Team Member of the project
projects, I did not meet any type of issue during successful designing of the electro magnetic
engine with our project team. I even had to guide two of my juniors, as this was their first
project, hence it showed my leadership and management skills.
CE 3.2.4 Group of People Involved in this Project
Figure 1: Team Members involved in this Work
CE 3.2.5 My main responsibilities as well as duties throughout the work
I was assigned for this particular project as the chief mechanical engineer. My main
duties included to propose a compact and accurate design for the respective electro magnetic

engine. I had to ensure that there is no utilization of any type of fuel like petrol or diesel and
also to reduce the overall need of any other energy. It also was supposed to reduce the costs
to a high extent and ensure that maximum advantages are gained in this process. My other
responsibilities included that each and every existing disadvantage of the conventional two
stroke engine and even making sure that the advantages are not reduced under any
circumstance. I had to research and take up proper understanding about electro magnetic
engines and how these engines work. I designed and constructed electrically operated
reciprocating motion or electromagnetic actuator.
CE 3.3 Distinct Activities in Work
CE 3.3.1 Comprehending the most Basic Theories Used within this Project
I had to utilize my basic theoretical understanding of electro magnetic engine and
process to implement it properly. I considered the working principle behind this proposed
mechanism. I understood that this principle lies within the concept of simple magnetism
properties, which are same poles repelling one another as well as opposite poles attracting
one another. This mechanism of electro magnetic engine majorly resembles the operating
principle of 2 stroke engine. I also checked that the coil is being linked through the battery
and the copper coil is being energized for producing the magnetic field. Specific piston
present inside comprises of the Neodymium Iron Boron magnet, the piston moves up
whenever the copper coil gets energized during the 1st time and it even moves down,
whenever coil is getting reenergized in the next time. For the core purpose of setting the
respective engine in momentum, the initial torque comprises to be provided. By taking the
relay as well as control unit, constant piston movement could be easily achieved.

Figure 2: Working Principle of Electromagnetic Engine
CE 3.3.2 Major Engineering skills or knowledge applied in the work
I had to apply my basic understanding for electromagnetic engine. The major
components of this project include cylinder, piston, fly wheel, permanent magnet, relay, timer
IC and battery. For understanding these requirements, it was extremely important to
understand the working principle of the engine. I had to apply my knowledge of statics and
dynamics, materials engineering, composites and solid mechanics to make the project a
successful one. Moreover, for my intense proficiency in Mathematics, I did not meet any
complexity while calculating the numerical analysis of the work.
CE 3.3.3 Execution of the work and Tasks Accomplished
I had to design as well as fabricate an electro magnetic engine, which would not
require consumption of any type of fuel, like petrol or diesel. A permanent magnet was being
used in the project, which can retain the magnetic properties in the absence of an inducing
field or current. In spite of having different types of magnets, I selected Neodymium-Iron-

Boron magnet, for its high performance, in comparison to the other magnets. Regarding
battery, I chose lead acid battery, with specifications as provided below:
Table 1: Specifications of the Lead Acid Battery
For the fabrication process, I considered few parts like metal cutting, machining
process, milling, welding and drilling. After completing the experiment, I had to compare the
theoretical as well as experimental value and it is provided below:
Table 2: Comparison between Experimental and Theoretical Values

CE 3.3.4 Identified issue with its solution
3.3.4.1 Issue faced in this work
The major issue that I had confronted in the work was while consideration of the
maximum power in electro magnetic engine. I took up extremely high power in the project
during initiation and as a result, our coil got burnt out. I was unable to save the coil and it
brought losses to my project.
3.3.4.2 Solution to the identified Technical Difficulty
As, it was my duty to fix up the respective issue, I decided to reconsider the power.
This time, I took up the maximum power of 0.00971 bhp and proper results were obtained.
The details are provided below:
PARAMETERS ELECTROMAGNETIC
ENGINE
ENGINE
DISPLACEMENT
97.00 cc
MAXIMUM POWER 0.00971 bhp
MAXIMUM TORQUE 0.5532 N-m
MAXIMUM RPM 125 rpm
Table 3: Final Parameters of the electromagnetic engine

CE 3.3.5 Plan made to give innovative as well as creative work
My distinctive strategy was to successfully design and fabricate the electromagnetic
engine with all types of original efforts and works with the respective team members. I also
gave duties to my juniors for making them parts of our work.
CE 3.3.6 Work Collaborations
I along with my team member and leader completed the project efficiently. I had
conducted formal meetings with the team member to get progress report on a weekly basis. I
even decided to consider the unique ideas of my team members for making the work more
efficient.
CE 3.4 Overall Reviewing of this Project
CE 3.4.1 Overviewing of this work
I had to document and note all project results while integrating all types of project
works. I eradicated the disadvantages of the engine like lesser durability, initial cost being
high, low flexibility, decreasing power of permanent magnet during time and getting replaced
in regular intervals.
CE 3.4.2 My Major Contributions
I proposed a complete and compact design of the electro magnetic engine so that it is
able to diminish the existing demerits and does not consume any type of fuel. After
successfully completing this particular project, I had to report to my project leader and
engineering department manager to update them regarding my work progress. Apart from
documenting the project report, I even took progress updates from my juniors.