Experimental Study of Cam Follower Based Power Generation

Abstract: The rapid depletion of conventional fossil fuels and the escalating global demand for clean energy have encouraged researchers to investigate small-scale, distributed electromechanical power generation systems. This project presents the design, fabrication, and experimental evaluation of a cam-follower-based power generation prototype that converts controlled reciprocating mechanical motion into usable electrical energy.
The system employs a 12 V DC geared motor operating at 45 RPM as the prime mover. The motor drives a profiled 90 mm cam, which actuates a spring-loaded follower shaft (12 mm diameter, 150 mm spring). A rack machined onto the follower shaft meshes with a pinion mounted on the shaft of a DC permanent-magnet generator, thereby converting the linear reciprocating motion into rotary generator input. The electrical output is rectified, stored in two series-connected 6 V DC batteries (12 V bus), and used to illuminate a 12 V DC LED module. The complete mechanism is mounted on a rigid frame fabricated from 1-inch mild-steel square pipes, with metal bushes providing precision linear guidance for the follower shaft.
Design calculations validate the cam kinematics, spring selection, rack-pinion gear ratios, frame structural integrity, and shaft stress. Experimental measurements of open-circuit voltage, loaded output voltage, and output current yield an average overall system efficiency of approximately 14%, consistent with expectations for a multi-stage electromechanical prototype. The project demonstrates a feasible, low-cost approach to mechanical energy harvesting and serves as a valuable educational platform for studying electromechanical conversion principles.

Keywords: Cam-Follower Mechanism, Energy Harvesting, Spring Design, Mechanical Power Generation.