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Pedal-operated generator for lighting

A compact human-power generator that lets you pedal to charge a 12 V battery and run LED lights/USB (optionally a small DC fan). It’s simple, safe, and perfect for labs, fairs, or off-grid lighting demos—showing mechanics (gear ratio, torque) and power electronics (rectifier, CC/CV charging, DC distribution).

Parts Used:

1.Mechanical

  1. Stationary bike/trainer stand or welded pedal frame
  2. Drive to generator: secondary chain/belt or knurled roller on tire
  3. Generator: PM DC motor or BLDC/e-bike hub motor used as generator
  4. Flywheel (optional) for smoother cadence, freewheel to allow coasting
  5. Guards, tensioner, adjustable motor plate

2.Electrical

  1. 3-phase bridge rectifier (for BLDC/PMA) + bulk capacitor (≥ 2200–4700 µF, 50–63 V)
  2. CC/CV charger (buck) set for 12 V battery (SLA 14.2 V; LiFePO₄ 14.6 V with BMS)
  3. Battery: 12 V deep-cycle SLA (20–40 Ah) or LiFePO₄ 12 V (10–20 Ah)
  4. DC load rail: 12 V LED bulbs/strips, rocker switches, USB buck (5 V)
  5. Meters & safety: DC wattmeter, fuse(s), main switch, dump/load resistor or over-voltage cut, proper wiring

TECHNICAL SUPPORT

Advantages:
  1. Hands-on energy: users “see” watts and runtime.
  2. Robust & simple: DC lighting avoids inverter complexity.
  3. Safe buffer: battery smooths output; lights don’t flicker.
  4. Modular: swap generators, ratios, and loads for lessons.