MIL Grow Crank Green: Mechanical Design and Analysis of a Low-Cost, Gear-Driven Hand-Cranked Generator Toolkit for Sustainable Global MIL Education
DOI:
https://doi.org/10.56220/uwjst.v9i.256Keywords:
Hand-Cranked Generator, SolidWorks Design, Off-Grid Power, Gear-Driven Mechanism, Sustainable Education.Abstract
High levels of energy poverty in emerging nations, educational infrastructure is one of the most sensitive areas that do not give students the opportunity to use digital facilities and means of communication. Traditional off-grid products, which include fossil-fuel generators and disposable batteries, are not economical or environmentally friendly. Moreover, the current hand-cranked devices are either plated into expensive military technology or cheap educational toys, which leave a gap of middle-range, durable solution. This study aims to design, analyze, and fabricate MIL Grow Crank Green, a low-cost (<$25), gear-driven, hand-cranked generator toolkit that encourages students to learn about energy and media literacy (MIL) while producing renewable electricity. SolidWorks CAD Software is used to Design the system optimizing an 80:1 compound gear train to analyze mechanical stress. A prototype permanent magnet alternator (PMA) is to be constructed and experimented with regarding voltage regulation, power output, and efficiency at varying resistive loads (10 ? -100 ?). The linear response of voltage (R2 =0.99) in operation is proven through experimental validation which provides a constant 3v-12v DC output. The system demonstrated a peak power output of 3.5W at a nominal load of 20?, with a mechanical-to-electrical efficiency of about 88% and managed to work and power LED arrays and mobile devices. The suggested model is an effective replacement to single-use batteries which are sustainable and strong. It enhances UN Sustainable Development Goals 4 (Quality Education) and 7 (Clean Energy) by bridging mechanical transparency to functional utility to enable off-grid communities to be energy literate.
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Copyright (c) 2025 Helal Uddin, Md. Rasel Ahmed, Touhidur Rahman Sajib, A Z M FUAD, Anjum Tasnim Totini, Rayhana Malik Senjuti
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