DESIGN AND CONSTRUCTION OF A 1kVA MICROCONTROLLER-BASED FUELLESS GENERATOR

The increasing demand for reliable and power supply has led to the development of alternative power solutions. This project focuses on the design and construction of a 1kVA microcontroller based fuelless generator, employing a generator instead of an inverter. The system converts stored DC energy from a battery into mechanical energy via a DC motor, which subsequently drives an AC generator to produce a stable 217V, 50Hz AC output (Figure 4.2). The design methodology involves the selection of appropriate components, including a 12V 75Ah battery bank, DC motor, alternator, bridge rectifier, voltage regulator, and Arduino Nano-based control circuit. Design calculations ensure optimal efficiency and performance, considering parameters such as power conversion, motor torque, generator sizing, and battery capacity. A MOSFET-based motor control circuit regulates the generator's operation, ensuring consistent AC output while providing dual charging capability through both internal generation and external charging systems. The constructed system undergoes rigorous testing under various load conditions ranging from 0 to 400W to assess its efficiency, voltage stability, and overall reliability. The results demonstrate that the generator-based approach offers an effective alternative to conventional inverters, particularly in applications requiring robust and uninterrupted power supply. The project provides a cost-effective, efficient, and scalable solution for backup power generation, making it suitable for both domestic and light industrial applications. The system achieved an average efficiency of 70.11% across different load conditions, with motor speed deviation of only 3.30% from the theoretical 1500 RPM and alternator output voltage deviation of 1.36% from the target 220V. The Arduino Nano-based control system successfully monitored critical parameters including battery voltage, charging current, load current, and motor RPM, displaying real-time information on a 20×4 LCD interface. Testing confirmed stable operation under varying load conditions (Table 4.1), validating the system's capability as a reliable electromechanical alternative to electronic inverter-based UPS systems.