Project Files of Hand Crank Generator Library for Proteus Simulation

HAND CRANK GENERATOR LIBRARY FOR PROTEUS SIMULATION - V1.0 (the 20 W emergency hand crank generator, with a pop-up)
Designed by The Engineering Projects
www.TheEngineeringProjects.com

IMPORTANT LINKS
Article (read it first - pictures, step by step, every feature explained):
  https://www.theengineeringprojects.com/2026/11/hand-crank-generator-library-for-proteus.html
Report a bug or suggest a feature (our forum):
  https://www.theengineeringprojects.com/forum/category/motor-driver-proteus-library
The demo runs on our Arduino UNO V4.0 (included) - working LEDs, RESET and a
built-in serial monitor, no Virtual Terminal to wire - its own article:
  https://www.theengineeringprojects.com/2026/10/arduino-uno-library-for-proteus-v40.html
The demo measures it with our INA219 library (installed from its own package - not in this zip):
  https://www.theengineeringprojects.com/2026/10/ina219-current-sensor-library-for-proteus-v1-0.html
Support us (the libraries are free):
  https://www.theengineeringprojects.com/donate

FILE STRUCTURE
Hand-Crank-Generator-TEP-v1.0/
|-- Proteus Library Files/
|   |-- ArduinoV4TEP.LIB                              201.9 KB   TEP Arduino boards V4.0 (UNO) -> LIBRARY
|   |-- TEPCRANK.LIB                                   13.3 KB   the library -> LIBRARY folder
|-- Proteus Model Files/
|   |-- TEPARDUINO.DLL                                883.5 KB   the Arduino board model -> MODELS folder
|   |-- TEPCRANK.DLL                                  317.0 KB   the model -> MODELS folder
|-- Proteus Simulation/
|   |-- Crank_Demo.hex                                 26.3 KB   the demo firmware
|   |-- CRANK-Generator-INA219-ArduinoUnoV4.pdsprj     20.9 KB   the demo project
|   |-- TEPARDUINO.DLL                                883.5 KB   copy of the board model
|   |-- TEPCRANK.DLL                                  317.0 KB   copy of the model
|-- Arduino Code/
|   |-- Crank_Demo/Crank_Demo.ino                       5.1 KB   the demo sketch (source of the .hex)
|-- README.txt                                        ~15.9 KB   this file
Total: 2.62 MB (unzipped). The C++ source code of the models is not included.

WHAT IS IT?
The 20 W hand crank generator of the emergency kits - a permanent-magnet generator behind a gear,
turned by a folding handle,
with a direct DC output - drawn at true scale from the handle's side (the olive metal housing 127 x
86 mm, the round gear cover,
the 80 mm crank arm with its knob, red and black leads; our own drawing, no maker's mark). Turn the
handle and it gives a voltage:
  * The voltage follows the cadence: 0.48 V for every turn a minute, behind 13.5 ohm inside. Both
    figures are set from the
    sellers' two points - 11.8 V 0.9 A at 50 turns a minute and 12.5 V 1.2 A at 60 - and give 28.8 V
    with no load at 60 turns a
    minute (the listings say "up to 28 V"). Its rectifier lets no current back in: a battery on the
    output cannot turn the handle.
  * The hand is modelled too. The load's current makes the torque the hand must give: 4.58 N.m for
    every ampere, plus 0.3 N.m of
    gear friction. The hand gives HAND newton metres at most (7 = about 88 N on the 80 mm handle); a
    load that asks for more
    slows the handle down until the two agree. A short circuit almost stops it, an open circuit lets
    it spin freely.
  * The hand's power against the load's: at 60 turns a minute into 10 ohm the load takes 15 W and
    the hand gives 37 W - the rest
    heats the winding. A lighter load is easier to turn and wastes less; the most power goes into a
    load of 13.5 ohm.
  * On the sheet the generator writes its cadence above the housing and its volts, amps and watts
    under it at Run. Click it at
    Run for the pop-up: the crank turning with the hand's push, the load line (volts and watts
    against current) with the working
    point and the matched point, eight live values; graphs, an event log and a check page.
The body is drawn as on the real part and to true scale against our Arduino.
The TEP signature and the pop-up are TEP additions.

ONE DEVICE (search "HANDCRANK" in Pick Devices):
  HANDCRANK20WTEP  "Hand Crank Generator 20 W V1.0" in TEPCRANK.LIB (Electromechanical >
  Generators), prefix HC, model
                   TEPCRANK.DLL (analog). Pins + and - on the left (the red and black leads). The
                   name starts with H so that it
                   sorts after the embedded ARDUINO UNO V4.0.

THE POP-UP
Click the part at Run. Tabs:
    Crank      chips: Stop, 30, 60, 90, 120 turns a minute; the hand: light (4 N.m), normal (7),
    strong (10); Demo. The generator
               from the handle's side with the arm turning and the hand's push at the knob (an
               orange arrow, longer the harder
               it pushes), the volts and amps at the leads; the load line at the present cadence:
               volts (green) and watts
               (orange) against the load's current, the matched point (ring), the working point, the
               line at 60 turns a minute
               (dashed); eight live values: the cadence and the asked one, the hand's torque and its
               force on the handle, the
               hand's power, the efficiency, the output, its power against the 20 W rating, the
               no-load volts and the most
               power a matched load would take, the energy and the turns so far.
    Graphs     the live values over the last 2, 6 or 15 s. Live / Freeze.
    Event log  every change and warning; filters All / Changes / Warnings, Pause, Clear
    Check      what the part is doing and what to look at, each with a verdict (green = fine, amber
    = check, red = wrong)
    Settings   theme, text size, open at Run, window size
    Help       report a bug, suggest a feature, article, updates, donate, forum; Copy diagnostics
    for a bug report

TEST STATUS
V1.0: verified in Proteus 8.5 on 16 Nov 2026 (the demo project as shipped: an A3 sheet, an Arduino UNO V4.0).
What the runs showed (the model's own numbers and the sketch's monitor):
The demo as shipped (Crank_Demo, the DEMO cadence, HAND 7 N.m, R1 10 ohm), one run (crfinal1), the
model's own pauses:
  * 30 turns a minute: 14.4 V inside, 6.16 V at 0.61 A, 3.8 W out; the hand gives 3.1 N.m (39 N on
    the handle), 9.7 W; 39 %.
  * 60 turns a minute: 28.8 V inside, 12.31 V at 1.22 A, 15.0 W out (the sellers' point: 12.5 V 1.2
    A); the hand 5.9 N.m (74 N), 37.1 W; 40 %; a matched load would take 15.4 W.
  * 90 turns a minute asked: THE HAND AT ITS LIMIT (7 N.m, 88 N) at 72 turns a minute: 34.5 V
    inside, 14.73 V at 1.46 A, 21.5 W out; the hand 52.6 W; 41 %.
  * 60 again: 12.31 V at 1.22 A, 15.0 W. The hand lets go at 8.3 s: at rest at 8.630 s.
  * The Event log's settled points: 0.890 s (3.8 W), 2.901 s (15.0 W), 4.803 s (21.5 W, with the
    warning), 6.639 s (15.0 W). In all 108.1 J to the load in 7 turns, from 267.3 J of the hand's
    work: 40 % overall. The most: 21.5 W, 1.46 A, 14.7 V.
  * The INA219 (U1) read 12.31 V at the supply, 121.89 mV on the shunt, 12.192 V on the bus, 1.219
    A; the monitor printed "Crank 12.31 V  1.22 A  15.0 W  about 60 rpm" and "about 72 rpm" at the
    limit, 110.5 J in all. 159 s for the 9.4 s of the run.

INSTALLATION (about 2 minutes)
1. Close Proteus. Extract the WHOLE ZIP to a normal folder (e.g. Desktop).
2. Copy everything in "Proteus Library Files" (TEPCRANK.LIB and our Arduino library V4.0,
ArduinoV4TEP.LIB, with the ARDUINO UNO V4.0 used by the demo) to the LIBRARY folder of Proteus, for
example:
     C:\Program Files (x86)\Labcenter Electronics\Proteus 8 Professional\LIBRARY
   (use the folder that already holds Proteus's own .LIB files).
3. Copy TEPCRANK.DLL and TEPARDUINO.DLL from "Proteus Model Files" to the MODELS folder (...\Proteus
8 Professional\MODELS).
4. Delete TEPCRANK.IDX from the LIBRARY folder if it is there (Proteus makes a new index).
5. Start Proteus. In Pick Devices (P) search "HANDCRANK".

RUN THE DEMO
"Proteus Simulation\CRANK-Generator-INA219-ArduinoUnoV4.pdsprj" (an A3 sheet) - keep the .hex file
and the DLLs beside the project.
  ARD1:   Arduino UNO V4.0 running Crank_Demo.hex, its serial monitor built in (window "TEP Arduino
  UNO - ARD1").
  U1:     our INA219 (its pop-up version) - the generator's + through its 0.1 ohm shunt into the
  load; SDA A4, SCL A5.
  R1:     10 ohm, the load (at 60 turns a minute it takes the sellers' 12.5 V 1.2 A point; use a 25
  W resistor on a real bench).
  HC1:    the generator, CRANK DEMO, HAND 7: 30 turns a minute from 0.3 s, 60 from 2.3 s, 90 asked
  from 4.3 s (the hand reaches
          its limit before that), 60 again from 6.3 s, the hand lets go at 8.3 s.
          The monitor prints the volts, amps, watts, the cadence worked out from them and the energy
          every half second; the UNO's
          LED lights at 12 V.
Closed the monitor? Click the UNO's USB port.

WIRING (the same in Proteus and on a real board)
  + to your load (here through the INA219's shunt), - to the load's ground. The output is not
  regulated: it follows the
  cadence. For 5 V or a battery put a regulator or a charge controller behind it.
REAL HARDWARE:
 * The output can pass 28 V with a light load and a fast hand: check what the load takes (the
   INA219's bus pin stops at 26 V).
 * Clamp the generator to a table or use its strap: a heavy load pushes back on the handle.
 * A 10 ohm load at 15 W needs a power resistor (25 W) - or use a 12 V car lamp.
 * Turn steadily: the voltage rises and falls with every change of pace; a battery or a large
   capacitor smooths it.

THE DEMO SKETCH ON THE SERIAL MONITOR (Crank_Demo V1.0, 9600 baud)
The sketch reports every 500 ms. Type a command:
  best       the most power so far       reset      forget it and the energy       rate 1000
  report every 1000 ms       help
EXPECTED MONITOR OUTPUT
  Hand Crank Generator (20 W) demo - The Engineering Projects
  Crank 6.16 V  0.61 A  3.8 W  about 30 rpm  energy 1.9 J
  Crank 12.31 V  1.22 A  15.0 W  about 60 rpm  energy 15.0 J  - 12 V reached
  Crank 14.73 V  1.46 A  21.5 W  about 72 rpm  energy 48.3 J  - 12 V reached       (90 asked: the
  hand at its limit)
  Crank at rest - turn the handle

PROPERTIES (double-click the part > Edit Properties)
  Handle (CRANK)                       turns a minute (0 - 150), or DEMO: 30, 60 and 90 turns a
  minute, 60 again, a stop (60)
  Hand (HAND)                          the most torque the hand gives, N.m, 2 - 12: the cadence
  falls when the load asks for more (7)
Every run starts again from the properties.

LINKS.INI (OPTIONAL)
The Help page cards of the pop-up open web pages. To point them somewhere else without a new DLL,
put a text file named links.ini next to TEPCRANK.DLL with lines KEY=URL, for example:
  ARTICLE=https://www.theengineeringprojects.com/...
Keys: WEBSITE, FORUM, BUG_REPORT, FEATURE_REQUEST, ARTICLE, USER_GUIDE,
UPDATE_CHECK, DONATE. Only http:// and https:// links are used; lines starting
with # are comments.

TROUBLESHOOTING
* No output: the handle is at rest (CRANK 0, or Stop in the pop-up).
* Fewer turns a minute than asked, HAND AT ITS LIMIT: the load is too heavy for this hand - raise
  HAND, or the load's resistance.
* OVER ITS RATING: more than 20 W (or 3 A) at the output - a real generator's winding overheats; use
  a lighter load.
* More than 28 V: a fast handle with a light load. That is real - the output is not regulated.
* The current does not reverse with a battery on the output: the rectifier blocks it, as in the real
  generator.
* The part is not simulated: TEPCRANK.DLL is missing from MODELS and from the project folder. No UNO
  / no monitor window: TEPARDUINO.DLL is missing, or click the UNO's USB port.

BUG REPORTS AND FEATURE REQUESTS
Please post them in our forum with a screenshot, the Serial Monitor text, the
simulation log and the pop-up's Copy diagnostics text:
  https://www.theengineeringprojects.com/forum/category/motor-driver-proteus-library

SUPPORT US
This library is free. If it saves you time, please support our work:
  https://www.theengineeringprojects.com/donate

WEBSITE
  https://www.theengineeringprojects.com/

LICENCES AND THIRD-PARTY NOTES
* The model (TEPCRANK.DLL), the symbols and artwork, the other parts of ours in the demo and the
  Arduino Library V4.0 (ArduinoV4TEP.LIB / TEPARDUINO.DLL, with its built-in TEP Serial Monitor
  Advance) are made by The Engineering Projects. The models use only standard Windows libraries; no
  Visual C++ redistributable is needed.
  The C++ source code is not included.
* Arduino UNO V4.0 (ArduinoV4TEP.LIB / TEPARDUINO.DLL, our Arduino Library V4.0 - its
  microcontroller is Proteus's own AVR model): The Engineering Projects,
  https://www.theengineeringprojects.com/2026/10/arduino-uno-library-for-proteus-v40.html
* The .hex file is built from the demo sketch and the Arduino AVR core 1.8.6, which includes
  LGPL-licensed code; its source code is available at
  https://github.com/arduino/ArduinoCore-avr/tree/1.8.6
* Proteus is a product of Labcenter Electronics and is not included. Arduino is a trademark of Arduino SA.
  This library is not made or endorsed by Arduino or Labcenter.

REBUILDING THE FIRMWARE (OPTIONAL)
The HEX file is supplied; Arduino IDE is not needed to run the demo. To edit the sketch, open
Arduino Code\Crank_Demo\Crank_Demo.ino, select Arduino Uno and use Sketch > Export Compiled Binary.
Replace the simulation's .hex with the exported HEX. The sketch needs 9,572 bytes of flash and 506
bytes of RAM.

MODEL SCOPE AND LIMITS
Modelled: the voltage by the cadence (0.48 V for every turn a minute) behind 13.5 ohm - both fitted
to the sellers' two points;
the rectifier (no reverse current), a 470 uF smoothing capacitor and a 4.7 kohm power lamp at the
output (our figures); the handle:
4.58 N.m for every ampere, 0.3 N.m of friction, the turning parts' inertia (0.02 kg.m2 at the
handle), an 80 mm arm (our figures);
the hand: it speeds up by 120 turns a minute each second, never brakes, and gives HAND newton metres
at most.
Not modelled: the ripple of the rectified output, the gear's noise and backlash, the winding's
heating (the rating is reported, not
simulated), a tiring hand, the uneven push of a real hand around the circle, the 5 V USB socket some
of these generators add.

VERSION
TEP Hand Crank Generator library V1.0 (Nov 2026). Device HANDCRANK20WTEP (TEPCRANK.LIB /
TEPCRANK.DLL). Demo sketch Crank_Demo V1.0 (the INA219 read straight with Wire). Demo board: ARDUINO
UNO V4.0 (TEP Arduino Library V4.0) with its built-in serial monitor.