Simulation and fabrication of a prototype mechanical footstep power generator for renewable energy applications
DOI:
https://doi.org/10.56862/irajtma.v4i3.329Keywords:
Mechanical Footstep Power Generator, Renewable Energy, Design for Assembly (DFA), Electrical OutputAbstract
The design and fabrication of a Mechanical Footstep Power Generator was developed as an innovative approach to harness kinetic energy from footsteps and convert it into electrical energy. Using a fabrication analysis and Design for Assembly (DFA) method, the prototype was designed to be both efficient and easy to assemble. The system consists of nine primary components, including the top plate, bottom plate, gear plate, gear, pinion, spring, dynamo (DC), long bolt M12, and nut. Fabricated parts were processed through tapping, drilling, milling, grinding, shaping, and chamfering, while other components were commercially purchased. DFA analysis indicated a medium level of assembly complexity, with potential errors mitigated by applying error proofing and systematic assembly guidelines. Experimental testing demonstrated a consistent increase in electrical output corresponding to the number of steps applied, starting from 2.96 V and 0.0074 W at the first step, reaching 5.71 V and 0.051961 W at the twentieth step. These results confirm that the prototype can reliably convert mechanical energy into electrical energy, though its application is currently limited to low-power usage. Nevertheless, the system presents significant potential for future development aimed at improving efficiency, capacity, and broader applicability in renewable energy solutions.
References
Abdullah, Ilmi, Bagus Giri Yudanto, Arjanggi Nasution, and Rendi Andiko. 2022. “Analisa Performansi Bahan Bakar Biogas Dan Bensin Terhadap Kualitas Pembakaran Pada Engine Genset 4 Tak 1 Silinder Kapasitas 80 Cc.” IRA Jurnal Teknik Mesin Dan Aplikasinya (IRAJTMA) 1 (1): 66–74. https://doi.org/10.56862/irajtma.v1i1.9.
Anggara, Fajar. 2020. “Validasi Nilai Simulasi Faktor Keamanan Pada Putaran Kritis Poros ST41.” Quantum Teknika : Jurnal Teknik Mesin Terapan 2 (1): 32–37. https://doi.org/10.18196/jqt.020120.
Azahari, Faiq Taquiddin, Maxmillain Newman Anak Atel, Siti Salwa Samsuri, and Azunaidi Abdul Aziz. 2023. “The Conceptual Design of An Electro-Magnetic Power Generator.” Semesta Teknika 26 (2): 231–39. https://doi.org/10.18196/st.v26i2.19404.
Basnet, Shirish, Kushal Ranabhat, and Min Narayan Shrestha. 2023. “Feasibility Study on Generation and Storage of Power Generated by Mechanical Footstep Power Generator” 2 (1): 93–96.
Brusa, Eugenio, Anna Carrera, and Cristiana Delprete. 2023. “A Review of Piezoelectric Energy Harvesting: Materials, Design, and Readout Circuits.” Actuators 12 (12). https://doi.org/10.3390/act12120457.
Cheng, Qun, Zhaonan Zhang, Yanwei Wang, and Lidong Zhang. 2025. “A Review of Distributed Energy Systems: Technologies, Classification, and Applications.” Sustainability (Switzerland) 17 (4): 1–31. https://doi.org/10.3390/su17041346.
Come Zebra, Emília Inês, Henny J. van der Windt, Geraldo Nhumaio, and André P.C. Faaij. 2021. “A Review of Hybrid Renewable Energy Systems in Mini-Grids for off-Grid Electrification in Developing Countries.” Renewable and Sustainable Energy Reviews 144 (December 2020). https://doi.org/10.1016/j.rser.2021.111036.
Farhat, Obeida, Jalal Faraj, Farouk Hachem, Cathy Castelain, and Mahmoud Khaled. 2022. “A Recent Review on Waste Heat Recovery Methodologies and Applications: Comprehensive Review, Critical Analysis and Potential Recommendations.” Cleaner Engineering and Technology 6:100387. https://doi.org/10.1016/j.clet.2021.100387.
Gołąbek, Justyna, and Michał Strankowski. 2024. “A Review of Recent Advances in Human-Motion Energy Harvesting Nanogenerators, Self-Powering Smart Sensors and Self-Charging Electronics.” Sensors 24 (4). https://doi.org/10.3390/s24041069.
Gunawardhana, K. R.Sanjaya D., Nandula D. Wanasekara, and R. D.Ishara G. Dharmasena. 2020. “Towards Truly Wearable Systems: Optimizing and Scaling Up Wearable Triboelectric Nanogenerators.” IScience 23 (8): 101360. https://doi.org/10.1016/j.isci.2020.101360.
Islam, Elaijah, Abu Musa Abdullah, Aminur Rashid Chowdhury, Farzana Tasnim, Carolina Olivares, Karen Lozano, and M Jasim Uddin. 2020. “Hybrid Triboelectric-Electromagnetic Energy Tile for Biomechanical Energy Scavenging.” Nano Energy 77:105250.
Jurmu, L., D. Robinette, J. Blough, and C. Reynolds. 2025. “Torque Converter Dynamic Characterization Using Torque Transmissibility Frequency Response Functions: Open Clutch, Hydro-Mechanical Response.” Experimental Techniques 49 (5): 811–27. https://doi.org/10.1007/s40799-025-00777-6.
Khan, Aqib, Mathieu Bressel, Arnaud Davigny, Dhaker Abbes, and Belkacem Ould Bouamama. 2025. “Comprehensive Review of Hybrid Energy Systems: Challenges, Applications, and Optimization Strategies.” Energies 18 (10): 1–34. https://doi.org/10.3390/en18102612.
Kou, L. Y., W. Y. Zhao, X. Y. Tuo, G. Wang, and C. R. Sun. 2020. “Effect of Stress Triaxiality on Fracture Failure of 6061 Aluminium Alloy.” Journal of Mechanical Engineering and Sciences 14 (2): 6961–70. https://doi.org/10.15282/JMES.14.2.2020.33.0545.
Lamin, Fauziana, Ahmad Kamal Ariffin, Intan Fadhlina Mohamed, and Cheeranan Krutsuwan. 2021. “Stress Flow Behaviour of AA2024 Under High-Pressure Torsion Deformation by Parametric Finite Element Analysis of Anvil Configuration.” Journal of Failure Analysis and Prevention 21 (6): 1951–60. https://doi.org/10.1007/s11668-021-01242-3.
Li, Peng, Hao Zhang, Xin Li, Zhanqun Shi, Sen Xiao, and Fengshou Gu. 2023. “Manufacturing Error and Misalignment Effect on the Transient Lubrication Behavior of Dynamically Loaded Journal Bearing with Micro-Groove.” Physics of Fluids 35 (7): 1–43. https://doi.org/10.1063/5.0157769.
Lin, Wenzhou, Yuchen Wei, Xupeng Wang, Kangjia Zhai, and Xiaomin Ji. 2023. “Study on Human Motion Energy Harvesting Devices: A Review.” Machines 11 (10). https://doi.org/10.3390/machines11100977.
Lopes Coelho, Ricardo. 2025. “Newton’s Second Law and Physics Textbooks.” Foundations of Science 2025 (May). https://doi.org/10.1007/s10699-025-09990-3.
Lv, Yongjun. 2023. “Transitioning to Sustainable Energy: Opportunities, Challenges, and the Potential of Blockchain Technology.” Frontiers in Energy Research 11 (September): 1–20. https://doi.org/10.3389/fenrg.2023.1258044.
Ma, Xun, Wubin Xu, Sun Jin, Xueping Zhang, and Bing Li. 2020. “Effects of Manufacturing Tolerances on Dynamic Properties of Journal Bearings.” IOP Conference Series: Materials Science and Engineering 717 (1). https://doi.org/10.1088/1757-899X/717/1/012010.
Mara, I M, H S Tira, T Rachmanto, and I M Nuarsa. 2025. “Experimental Study of the Effect of Load and Vehicle Speed on Energy Consumption of Electric Vehicles” 15 (2): 152–58.
Radhakrishnan, Ganesh, Daniel Breaz, Sami Sulaiman Al Khusaibi, Amjad Juma Al Subaihi, Al Azhar Zahir Al Ismaili, Al Salt Malik AlMaani, and Kadhavoor R. Karthikeyan. 2023. “Experimental and Numerical Study on the Influence of Stress Concentration on the Flexural Stability of an Aluminium Hollow Tube.” Materials 16 (4). https://doi.org/10.3390/ma16041492.
Saba, Hugo, Filipe Cardoso Brito, Rafael Guimarães Oliveira dos Santos, Toni Alex Reis Borges, Raíssa Silva Fernandes, Márcio Luís Valenca Araujo, Eduardo Manuel de Freitas Jorge, et al. 2024. “The Potential Related to Microgeneration of Renewable Energy in Urban Spaces and Its Impact on Urban Planning.” Energies 17 (23): 1–19. https://doi.org/10.3390/en17236018.
Sebestyén, Viktor. 2021. “Renewable and Sustainable Energy Reviews: Environmental Impact Networks of Renewable Energy Power Plants.” Renewable and Sustainable Energy Reviews 151 (December 2020): 111626. https://doi.org/10.1016/j.rser.2021.111626.
Selim, Kyrillos K., Idris H. Smaili, Hossam M. Yehia, M. M.R. Ahmed, and Demyana A. Saleeb. 2024. “Piezoelectric Sensors Pressed by Human Footsteps for Energy Harvesting.” Energies 17 (10): 1–13. https://doi.org/10.3390/en17102297.
Sezer, Nurettin, and Muammer Koç. 2021. “A Comprehensive Review on the State-of-the-Art of Piezoelectric Energy Harvesting.” Nano Energy 80 (October 2020): 105567. https://doi.org/10.1016/j.nanoen.2020.105567.
Shin, Dongil, and Alan B. Palazzolo. 2021. “Tilting Pad Journal Bearing Misalignment Effect on Thermally Induced Synchronous Instability (Morton Effect).” Journal of Tribology 143 (3): 1–19. https://doi.org/10.1115/1.4048164.
Tabaie, Zahrasadat, and Amir Omidvar. 2023. “Heliyon Human Body Heat-Driven Thermoelectric Generators as a Sustainable Power Supply for Wearable Electronic Devices : Recent Advances , Challenges , and Future Perspectives.” Heliyon 9 (4): e14707. https://doi.org/10.1016/j.heliyon.2023.e14707.
Türkay, Alperen, and Fatih Altun. 2023. “Comparison of Critical Torque Values of Reinforced Concrete Walls Obtained from Tests, Finite Element Analyses and Various Standards.” International Journal of Civil Engineering 21 (7): 1181–94. https://doi.org/10.1007/s40999-023-00815-7.
Uddin, Moslem, Huadong Mo, Daoyi Dong, Sondoss Elsawah, Jianguo Zhu, and Josep M. Guerrero. 2023. “Microgrids: A Review, Outstanding Issues and Future Trends.” Energy Strategy Reviews 49 (February). https://doi.org/10.1016/j.esr.2023.101127.
Wang, Yi, Guoyun Lu, and Fenghui Dong. 2025. “Probabilistic Safety Factor Assessment of Composite Pile Foundation Using Symmetrical FEM Reliability Method.” Buildings 15 (7): 1–20. https://doi.org/10.3390/buildings15071020.
Yao, Mingliang, Guangzhong Xie, Qichen Gong, and Yuanjie Su. 2020. “Walking Energy Harvesting and Self-Powered Tracking System Based on Triboelectric Nanogenerators.” Beilstein Journal of Nanotechnology 11:1590–95. https://doi.org/10.3762/BJNANO.11.141.
Zaidi, Syed Azfar Imam, Shahid Iqbal, Fahad Hussain, Muhammad Hammad Ikram, Waqas Javid, and Muhammad Mateen. 2024. “A Novel Low-Cost Mechanism for Energy Generation through Footsteps.” In , 18. https://doi.org/10.3390/materproc2024017018.
Downloads
Published
How to Cite
Issue
Section
License
Copyright (c) 2026 IRA Jurnal Teknik Mesin dan Aplikasinya (IRAJTMA)
This work is licensed under a Creative Commons Attribution-ShareAlike 4.0 International License.
