FABRICATION OF

WATER FUELLED VEHICLE

NAME OF THE GUIDE : Mr. P.SRINIVAS RAO, M.Tech

ASSOCIATE PROFESSOR, MECHANICAL DEPARTMENT

PROJECT BY : KARI JAGADISH

BACHELOR OF ENGINEERING (B.E)

MECHANICAL ENGINEERING(2011-2015)

RAGHU INSTITUTE OF TECHNOLOGY

VISAKHAPATNAM.

ABSTRACT

A Water fuelled Vehicle is an alternative fuel vehicle that uses “Oxyhrogen or HHO Gas” as its onboard fuel

for motive power. Combustion of hydrogen with air is receiving increasing attention in the future energy

scenario.

The term may refer to a personal transportation vehicle, such as an automobile, or any other vehicle that

uses hydrogen in a similar fashion, such as an aircraft. The power plants of such vehicles convert the

chemical energy of hydrogen to mechanical energy either by burning hydrogen in an internal combustion

engine (spark ignition engine), Widespread use of hydrogen for fueling transportation is a key element of a

proposed hydrogen economy.

Hydrogen fuel does not occur naturally on Earth and thus is not an energy source, but is an energy carrier.

Currently it is most frequently made from methane or other fossil fuels. However, it can be produced from a

wide range of sources (such as wind, solar, or nuclear) that are intermittent, too diffuse or too awkward to

directly propel vehicles. Integrated wind-to-hydrogen plants, using electrolysis of water, are exploring

technologies to deliver costs low enough, and quantities great enough, to compete with traditional energy

sources.

INTRODUCTION

A water-fuel generator that will convert the water into an extremely powerful, clean burning gas!

An Hydrogen generator, like this one, uses electricity from your car battery to split water into

hydrogen and oxygen gasses. Together, these make a fuel that is much more powerful than

gasoline, and the only emission released is “water vapour”

It does this by using some current from the cars battery and alternator to fracture water

into a mixture of hydrogen and oxygen gasses called HHO hydroxy gas which is then added to

the air which is being drawn into the engine.

AIM OF THE PROJECT

The Main Aim of the Project is to make a Non-Polluting Vehicle which is Eco-Friendly and

should fully function on “Water (H2O)” by using a HHO Generator.

We will learn how to use HHO Gas to reduce fuel consumption and pollution and how to properly

tune the vehicle to work with those changes.

HHO Generator could be easily created and installed on a car or truck, it improves the attributes

of both gasoline and diesel engines.

This device produces a lot of hydrogen/oxygen gas on low amperage and even make you save

fuel when not connected to power supply!

Only small amount of HHO Gas is required to improve the combustion so with the correct

electrolysis cell and proper fine tuning to the ignition system the additional load on the alternator

is be minimal.

DESCRIPTION OF THE WORK

The HHO Generator is a piece of equipment which increases the mpg performance of a car or

motorcycle, and reduces the harmful emissions dramatically. It does this by using some current from

the vehicle’s battery to break water into a mixture of hydrogen and oxygen gases called “hydroxy” gas

which is then added to the air which is being drawn into the engine.

The hydroxy gas improves the quality of the fuel burn inside the engine, increases the engine power,

cleans old carbon deposits off the inside of an old engine, reduces the unwanted exhaust emissions

and improves the mpg figures under all driving conditions, provided that the fuel computer does not

try to pump excess fuel into the engine when it detects the much improved quality of the exhaust.

This HHO Generator is easy to make and the components don’t cost much. The technical performance

of the unit is very good as it produces 1.7 to 2.0 litres of hydroxy gas per minute at a managable amp

current load and one litre of water could be split into a mix of 1800 litres of Hydrogen-Oxygen

gas at a very reasonable current draw.

SCOPE

HYDROGEN IS THE KEY TO A CLEAN ENERGY FUTURE:

It has the highest energy content per unit of weight of any known fuel.

When burned in an engine, hydrogen produces effectively zero emissions; when powering a fuel cell, its only waste is water.

Hydrogen can be produced from abundant domestic resources including natural gas, coal, biomass, and even water.

Combined with other technologies such as carbon capture and storage, renewable energy and fusion energy, fuel cells could make an emissions-free energy future possible.

PLANNING AND SCHEDULING

CUTTING OF STEEL PLATES BY STEEL CUTTING MACHINE

DRILLING THE STEEL PLATES

ASEEMBLY OF THE STEEL PLATES

ELECTRIC CONNECTION

INSULATING THE PLATE ASSEMBLY

DRILLING THE CUP

CUP ASEMBLY

PLANNING AND SCHEDULING

BUBBLER CONSTRUCTION

ASSEMBLY OF THE BUBBLER TO THE MAIN GENERATOR BODY

ADJUSTING THE ELECTROLYTE

FINAL ASSEMBLY

POWERING THE GENERATOR WITH ELECTRICAL CONNECTION

PLACING AND CONNECTING THE GENERATOR

FINAL TEST ON VEHICLE

LITERATURE SURVEY

We need to stop burning fossil fuels. If we do so, it leaves us with two problems, namely, a way to generate

power to run our electrical equipment and heat or cool our homes, and a way to power our vehicles. In this document,

we will consider the question of powering vehicles.

There are two main options.

The first is to achieve a reduction in the amount of fossil fuel burnt. The second is to eliminate the use of fossil

fuel altogether. Both have been achieved. As an example of the first option, consider a car powered by a petrol (gasoline)

engine. In the average car, only 35% or so of the fuel is burnt in the cylinders of the engine, the remaining 65% burns in the

catalytic converter or is pushed, unburnt, out of the exhaust pipe as major pollution.

Reducing the fuel used:

It is possible to reduce the amount of fuel used, by utilising any or all of the following:

1. Improving the quality of the burn.

2. Reducing the amount of fuel in the cylinder.

3. Introducing water vapour into the cylinder.

4. Improving the quality of the spark.

5. Improving the streamlining of the vehicle

HHO GENERATOR PARTS Part Quantity Comment

4-inch diameter Acrylic pipe 12-inches long 1 Forms the body of the booster

4-inch diameter PVC pipe end-cap 1 Closes the bottom of the booster

4-inch diameter PVC pipe screw cap 1 The top of the booster

90-degree Quick Connect Outlet fitting 1 3/8" O.D. Tube x 1/4" NPT from Hardware store

Level indicator Nylon barbed tube fitting 2 1/4" Tube x 1/8" NPT Part Number 2974K153 or from your local hardware store

Quarter-inch I.D. Poly sight tube 8” Water-level indicator tubing - Hardware store

Stainless steel switch covers 16 The plate array components

Stainless steel straps 12-inches long 2 The electrical connections to the plates

3/4" Inside Diameter Clear poly tube 12-inch From your local hardware store

5/16” stainless steel bolts 1.25” long 2 Electrical strap connection to the top cap

5/16” stainless steel nuts & washers 6 each To fit the steel bolts in the cap

5/16” diameter nylon threaded rod 8” min. Nylon Threaded Rod 5/16"-18 Thread.

5/16” inch nylon washers 1.6 mm thick 1-pack Nylon 6/6 Flat Washer 5/16", Pack of 100 McMaster Carr Part No 90295a160

5/16”-18 s/s jam nuts (7/32" thick) 20 McMaster Carr Part No 91841A030

90 degree Bubbler Fittings 2 1/4" Barbed Tube 1/2" NPT. McMaster Carr Part No 2974K156

Check valve 1 1/4" tube, McMaster Carr Part No 47245K27 or from your local Hardware store

PVC glue 1 tube Same color as the PVC pipe if possible

5/16" Neoprene sealing washer 2 McMaster Carr Part No 94709A318 or from your local Hardware store

Tool dip – 14.5 oz 1 McMaster Carr Part No 9560t71

Optional: Light Emitting Diode 1 10 mm diameter, red, with panel-mounting clip

Nylon Pipe : SWIVEL ELBOWS :

ACRYLIC PIPES WITH END CAPS : STAINLESS STEEL PLATES AND STRAPS :

DIFFERENT PARTS OF GENERATOR :

CONSTRUCTION OF HYDROGEN GENERATOR

PREPARATION OF STEEL PLATES :

We use 20 gauge stainless steel, and with the help

of the drilling machine we make holes at top and

bottoms of the plates.

When finished, I had 12 plates measuring 3" x 6", 4

plates at 1-1/2" x 6", and three 1" connector bands

that were 6", 4-1/2", and 3 1/4".

A Grinding machine was used for smoothing down

the jagged edges around the hole and edges of the

plates.

STEEL PLATES ASSEMBLY :

The plates are joined in this configuration, using

plastic rods, plastic washers, and stainless steel nuts

to make the proper electrical connections. Then a

4" ABS clean out plug was attached at the top with

some stainless steel bolts.

I attached a swivel elbow to the top of the cap, and

the main generator is finished.

Next I used 100 grit sandpaper to sand each of the

plates diagonally.You can see the "X" pattern I

sanded into both sides of the plates. This increases

the surface area of the plate, and will assist in

producing more gas.

MAIN GENERATOR BODY ASSEMBLY :

• The plate assembly which is fitted to the

end cap is get assembled with the 4 inch

Acrylic pipe and thus the assembly of

main generator body is finished.

• The Generator body consists of a Pressure

Guage and swivel elbow(to which nylon

tube is connected)

MAKING OF THE ELECTROLYTE :

The electrolyte is distilled water and about

2-4 teaspoons of KOH (potassium

hydroxide). Salt or baking soda could also

be used, but may dirty the plates over

time.

The Electrolyte is get purified with the

filter paper such that all the dirt present

inside the electrolyte is get removed and

the electrolyte is poured inside the

Generator body.

COMPLETE ASSEMBLY OF HYDROGEN GENERATOR AND TESTING :

The Generator is get connected

with the bubbler in which a Air

check valve is present in between

Generator and bubbler.

The Power supply is given by

means of a 12 volts battery with

electrical wires connection.

The current is measured by means

of Multimeter.

HYDROGEN GENARATOR INSTALLATION TO THE BIKE :

The HHO gas which comes from the

bubbler is get connected to the Air

intake valve or carburretor of the

vehicle.

Such that the Gas get ignited inside the

combustion chamber of the Engine

and then the vehicle runs.

The exhaust pollutant will be the water

vapour.

FEEDBACK AT EVERY STEP

Thus we bulit a Hyrogen generator with the

help of guide and team work and the results

were quite satisfying.

It’s a Green technology and eco-friendly

because it is pollution free.

RESULT ANALYSIS

HHO Generator uses electrolysis to split water (H2O) into it´s base molecules, 2 hydrogen and 1 oxygen molecule. This is why it is often referred to as an HHO gas generator.The HHO in itself is not an alternative to gasoline but a additive to boost the efficiency of the engine. Gasoline engines are unfortunately not burning gasoline to its full potential.

The average gasoline engine in a car is about 18% to 20% efficient. That leaves a lot of room for improvement and Brown gas is one good way of improving the efficiency. The reason for this is simple, the hydrogen is highly flammable much more so than gasoline so when your engine ignites the hydrogen the explosion ignites the gasoline with much better results (cleaner, less waste and fewer emissions) than it would otherwise have done.

Some basics the burn speed of hydrogen is 0.098 to 0.197 ft/min (3 to 6 cm/min) compared gasoline´s 0.00656 to 0.0295 ft/min (0.2 to 0.9 cm/min).

The hydrogen explosion is so fast that it fills the combustion cylinder at least 3 times faster then the gasoline explosion and subsequent ignites the gasoline from all directions (it is like putting flue on a fire), instead of just a spark in one end of the combustion cylinder, and we would like to do that because the gasoline only has a short time in the combustion cylinder and if its not fully burnt in that short amount of time then it just goes out the exhaust and is lost.It is also preferable to ignite all of the gasoline when it is under maximum compression in combustion cylinder to get the maximum amount of energy out of it ,when once the piston starts going down the energy transfer from the explosion to the engine becomes less efficient.

The hydrogen´s higher burn temperature and explosive force is such that it cleans the soot that collects in the engine (it is like having the engine consistent maintains) and with a cleaner engine you get better mileage and fewer oil changes

CONCLUSION The new generation of hydrogen generators comes with extremely highpurity devices, that are safe and that present

no danger to the environment. They are the best alternative to gas cylinders, and they are simple to use anywhere. The

HHO Generator just needs to be plugged in the electrical supply and it is ready to go.

The hydrogen generator need of course a source of distilled water, or justwater at some models, to produce hydrogen,

because it separates the hydrogen from the oxygen in the water, thus producing highly pure hydrogen for weeks.

These hydrogen generators can generate hydrogen that is 99.99..% pure, giving over 1000 cc/min, and they do not

require changing their cylinders.

The safety of the hydrogen generators has been certified. How the hydrogen generator works may vary from

manufacturer to manufacturer, for example some models use a solid polymer electrolyte to from hydrogen, which

makes them more safe than other models that use acaustic liquid electrolyte. After the hydrogen is generated it passes

through a palladium membrane that lets only 99.99% pure hydrogen pass through, thus insuring the gas' purity.

In conclusion, the latest generation of hydrogen generators brings some series of improvements that makes it extra

reliable, with almost no need of maintenance or downtime.The best way of increasing the safety and lowering the

costs in the laboratory is to acquire a hydrogen generator, and we can be sure that the investment is worth it, because

we will no longer have to buy hydrogen cylinders, so the hydrogen generator will pay for itself in a year or two.

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