Cal Poly’s Recreation Center expansion project provides an opportunity to implement Energy Harvesting From Exercise Machines (EHFEM). Part of this implementation is a system that reports the exercise machines’ energy production. Although products capable of reporting exercise machine energy harvesting statistics exist, they have limited capabilities. This thesis project defends a system capable of reporting exercise machine power statistics in near real-time. The system consists of display, database, and power measurement modules. The display module presents statistics in an interactive, graphical, and widely-accessible way. The database module provides an efficient way of organizing and accessing stored statistics. Multiple power measurement module types gather power and energy generation measurements from multiple exercise machine types and transmit those measurements to the database module over the computer network.

This thesis presents an active clamp forward converter for use in the Energy Harvesting From Exercise Machines project. Ideally, this converter will find use as the centerpiece in a process that links elliptical trainers to the California grid. This active clamp forward converter boasts a 14V-60V input voltage range and 150W power rating, which closely match the output voltage and power levels from the elliptical trainer. The isolated topology outputs 51V, higher than previous, non-isolated attempts, which allows the elliptical trainers to interact with a central grid-tied inverter instead of many small ones. The final converter operated at greater than 86% efficiency over most of the elliptical trainer’s input range, and produced very little noise, making it a solid choice for this implementation.