Department of Mechanical Engineering
Swedish College of Engineering & Technology
Wah Cantt
(Affiliated with University of Engineering & Technology Taxila)
Design and Fabrication of Electricity Generation from Speed breaker
SESSION 2010-2014
PROJECT SUPERVISOR
Engr. Shehriyar Ahmed
SUBMITTED BY
Zeeshan Nawaz UET10-ME-SCET-01
Muhammad Zeeshan UET10-ME-SCET-25
Abubakr Saleh UET10-ME-SCET-10
In the Name of Allah, Most Gracious, Most Merciful
O my Lord, Cool My Temper.
And make this matter Easy for Me.
And Unite a Knot from My Tongue.
So, they can Understand My Speech.
AL-QURAN (20:25-28)
As partial fulfillment of the requirements for the
Bachelor's Degree
In
Mechanical Engineering
This report is submitted to
The Mechanical Engineering Department
Swedish College of Engineering & Technology
Wah Cantt
____________________ _______________________
Internal Examiner External Examiner
___________________
Head of Department
Mechanical Engineering
Department of Mechanical Engineering
Swedish College of Engineering & Technology
Wah Cantt
(Affiliated with University of Engineering & Technology Taxila)
DECLARATION
We declare that the work contained in this thesis is our own, except where explicitly stated otherwise. In addition this work has not been submitted to obtain another degree or professional qualification.
Signed: ______________________
Zeeshan Nawaz
Signed: _______________________
Muhammad Zeeshan
Signed: ________________________
Abubakr Saleh
Department of Mechanical Engineering
Swedish College of Engineering & Technology
Wah Cantt
(Affiliated with University of Engineering & Technology Taxila)
ACKNOWLEDGEMENT
First of all we thank Allah Almighty for giving us the strength and ability to complete this project thesis.
We would like to thank our supervisor Engr. Shehriyar Ahmed for his guidance and support through-out the course of this thesis. We would also like to thank faculty of electrical department who helped us in electrical portion of our project. We are thankful to lathe operator Muhammad Abid who helped a lot in fabrication process. And we are thankful to other class fellows, teachers. Lab-operators who guided us well.
At the end special thanks to our parent for without their support and prayers it would not have been possible.
______________________________________________________________________________
Authors
DEDICATED
With a sense of thankfulness to our
"Beloved Parents"
Whom parental love and selfless
Devotion to the cause of
Our well-being and sources of
Inspiration to us
But have also inculcated in us a zest
Of knowledge and learning
And a deeper sense of duty towards
Our country and fellow being
"To our Teachers"
From them we learnt continuously
Throughout the time we were here
And who guided and stimulated us
Throughout our educational career
ABSTRACT
An energy crisis may be referred to as an oil crisis, petroleum crisis, energy shortage, electricity shortage, electricity crisis. So an alternative energy source is required which is cheap, no natural input source is required to generate electricity. This project is about GENERATION OF ELECTRICITY using SPEED BREAKERS.
In this project a mechanism to generate power by converting the potential energy generated by a vehicle going up on a speed breaker into electricity. When the vehicle moves over the inclined plate, it gains height resulting in increase in potential energy, which is wasted in a conventional speed breaker. When the breaker comes down, the rack and pinion mechanism (translatory to rotary motion converter) is fitted beneath. This in turn rotates a fly wheel at the middle of shaft which rotates a gear at the end of the shaft and then rotation transfer to gear train (rpm increased). The output of this gear train is coupled to a generator to convert rotational energy into electricity. A vehicle weighing 1,000 kg going up a height of 10 cm on such speed breaker produces approximately 0.98 kilowatt power. So one such speed-breaker on a busy highway, where about 100 vehicles pass every minute, about one kilowatt of electricity can be produced every single minute.
Contents
Chapter 1 10
1.1 INTRODUCTION 10
1.2 How Electric Speed breaker Works? 10
1.3 History 10
1.4 Advantages 11
1.5 Ways to produce electricity. 11
1.5.1Electricity generating arm-band 11
1.5.2 Convert work out sweat into electricity 11
1.5.3 Generating Electricity While Washing Your Car 12
1.5.4 Charge your iPhone while playing golf 12
1.5.5 Roll Kinetic Charger to juice up your batteries 13
1.6 Types of Mechanisms 14
1.6.1 ROLLER MECHANISM 14
1.6.2 CRANKSHAFT MECHANISM 15
1.6.3 WORKING OF RACK-PINION MECHANISM 16
CHAPTER 2 18
LITERATURE VIEW 18
2.2 Main components of Our Project 20
2.3 Rack 20
2.4 Gears 20
2.4.1General Terminologies of Gears 20
2.5.2 Types of Gears 23
1. Spur Gears 23
2. Bevel Gears 24
3. Helical Gears 24
4. Worm Gears 24
2.6 Shaft 25
2.7 Bearings 25
2.8 Fly wheel: 25
2.9 Spring: 25
2. 10Generator 25
Chapter #3 26
DESIGN WORK 26
26
CHAPTER 4 30
PHYSICAL MODELING 30
4.2 ASSEMBLING PHASE 34
CHAPTER 5 36
FABRICATION SUMMARY 36
1. Frame: 36
5.1 PARTS OF SPEED BREAKER 37
1. Shaft 37
2. Bearing 38
3. FLANGE 39
5. Flywheel: 39
6. Metal sheet: 40
7. Spring: 40
7. Helical Gears 41
8. Rack and pinion: 42
9. Bolt and Nut 44
10. Bushes: 44
11. Generator: 45
12. L.ANGLES 46
13. Bicycle Flywheel 46
14. Electrical Accessories 47
Chapter # 6 60
6.1 Result and conclusion 60
6.2 Model calculation 60
6.3 Actual Calculation 61
6.4 Conclusion 61
6.5 What We Achieve ? 62
6.6 Future scope of this project 62
( EVERY SPEED BREAKER IS NOW A SOURCE OF POWER) 63
Speed Bumps Harvest Electricity from Moving Cars by Sarah Parsons, 09/08/09 63
List of Figures
Figure 1 12
Figure 2 13
Figure 3 13
Figure 4 14
Figure 5 15
Figure 6 16
Figure 7 Rack & pinion 17
Figure 8 block diagram 18
Figure 9 gear 20
Figure 10 23
Figure 11 bevel gear 23
Figure 12 helical gear 23
Figure 13 worm gear 24
Figure 14 rack 25
Figure 15 pinion 26
Figure 16 box 26
Figure 17 breaker 26
Figure 18 dome 27
Figure 19 gear 27
Figure 20 shaft 28
Figure 21 motor 28
Figure 22 spring 28
Figure 23 shaft assembly 29
Figure 24 gear and box 29
Figure 25 dome and box assembly 30
Figure 26 breaker and box 30
Figure 27 explode view 31
Figure 28 complete view 31
Figure 29 shaft 33
Figure 30 bearing 33
Figure 31flange 34
Figure 32 flywheel 35
Figure 33metal sheet 35
Figure 34 spring 36
Figure 35 37
Figure 36 37
Figure 37rack 38
Figure 38 bolt and nut 39
Figure 39 bushes 40
Figure 40 40
Figure 41 generator 41
Figure 42 L-angle 41
Figure 43 42
Figure 44 electrical accosseries 42
Figure 45 breaker 42
Figure 46 marking 43
Figure 47 cutting 43
Figure 48 holing 43
Figure 49 drilling 44
Figure 50 hole 44
Figure 51 grinding 44
Figure 52 fixing 44
Figure 53 Machining 45
Figure 54 keyway 45
Figure 55 keyway 45
Figure 56 gear making 46
Figure 57 Making flywheel 46
Figure 58 working 46
Figure 59 Mount gear on shaft 47
Figure 60 Mounting flywheel and gear 47
Figure 61 hinge the shaft 1 47
Figure 62 hing the shaft 2 48
Figure 63 mount both shaft 48
Figure 64 making frame 48
Figure 65 outer flywheel 49
Figure 66 joining the rack 49
Figure 67 rack supporter 49
Figure 68 bushes 50
Figure 69 spring assembly 50
Figure 70 spray 50
Figure 71 generator 51
Figure 72 placing breaker 51
Figure 73 paint the breaker 51
Figure 74 final assembly 52
Figure 75 paint full assembly 52
Figure 76 electrical assembly 52
Figure 77 wire description 53
Figure 78 wire coupling 54
Figure 79 view 1 55
LIST OF TABLES
Table 1 31
Table 2 31
Table 3 32
Table 4 32
Table 5 33
Table 6 34
Table 7 34
Table 8 36
Table 9 36
Table 10 37
Table 11 37
Table 12 39
Table 13 39
Chapter # 1
INTRODUCTION
1.2 How Electric Speed breaker Works?
The number of vehicles on road is increasing rapidly and if we convert some of the Potential energy of these vehicle into the rotational motion of generator then we can produce considerable amount of electricity, this is the main concept of this project. At present we are facing shortage of electricity.
Electricity can be generated using speed breakers, strange, isn't it? The benefits from this idea will be to generate electricity for the streetlights, hoardings and then for other use.Generally when vehicle is in motion it produces various forms of energy like, due to friction between vehicle's wheel and road i.e. rough surface "HEAT Energy" is produced, also when vehicle traveling at high speed strikes the wind then also heat energy is produced which is always lost in environment and of which we can't make use of….OR directly we can say that all this energy that we can't make use of is just the wastage of energy that is abundantly available around us. In this project we are just trying to make use of such energy in order to generate an "ELECTRICAL ENERGY". This project will work on the principle of "POTENTIAL ENERGY TO ELECTRICAL ENERGY CONVERSION" Potential energy can be thought of as energy stored within a physical system.
1.3 Why We Have Selected This Project
The current demand of electricity is 12,850 MW, while hydro power production is 2820 MW; thermal resources produce 1800 MW; production through independent power producers (IIPs) is 5030 MW, which amounts total production of 9630 MW.
The total current shortfall despite the fact that changing weather has decreased the demand of electricity, has reached 3250 MW, claimed National Transmission and Dispatch Company (NTDC) authorities.
Since this mechanism is convenient to produce ample amount of energy with maximum efficiency, we have chosen this method for our project with a very simple and effective design for generating electricity using a rack and pinion mechanism.
1.4 Advantages
Pollution free power generation.
Simple construction, mature technology, and easy maintenance.
No manual work necessary during generation.
Energy available all year round.
No fuel transportation problem
.
1.5 Ways to produce electricity.
1.5.1Electricity generating arm-band
A mobile phone charger is powered by dance energy. The kinetic movement of a system of weighs and magnets, which move as you groove, powers the charger. It weighs just 180 grams and can be strapped on the dancer's bicep. The energy generated while dancing can be fed into your cell phones when the batteries run dry
1.5.2 Convert work out sweat into electricity
The energy from this power generating gym is converted from DC to AC before being transferred into the grid. The output is considerably small; a person pedaling 30 minutes would generate energy to run a laptop for approximately an hour.
Hence using this concept energy lost by people in gyms and aerobics daily can be efficiently used to light up the gym as well as run few appliances like laptop, radios .etc.
Figure 1
1.5.3 Generating Electricity While Washing Your Car
Figure 2
You can recharge your electric car batteries while washing them, using nothing other than the energy of water in the hosepipe, eventually reducing your electricity bills. The device envisioned by Vandenbussche, POWA Water Generator, is a small turbine that is placed in between the hosepipe. As the water rushes through the pipe it turns, the blades of the small turbine that then generate electricity that can directly be fed into the car.
1.5.4 Charge your iPhone while playing golf
Figure 3
The gadget designed by Mac Funamizu harnesses the kinetic energy the user generates, when the grip is swung a certain number of times, that can be later used to charge mobile phones and other gadgets for a couple of hours.
1.6 Types of Mechanisms
We can develop electricity from speed breakers by using 3 Mechanisms basically
They are as follows:
1) Roller mechanism
2) Crank-shaft mechanism
3) Rack-pinion mechanism
1.6.1 ROLLER MECHANISM
In this Mechanism, a roller is fitted in between a speed breaker and some kind of a grip is provided on the speed breaker so that when a vehicle passes over speed breaker it rotates the roller. This movement of roller is used to rotate the shaft of D.C. generator by the help of chain drive which is there to provide different speed ratios. As the shaft of D.C. generator rotates, it produces electricity. This electricity is stored in a battery. Then the output of the battery is used to lighten the street lamps on the road. Now during daytime we don't need electricity for lightening the street lamps so we are using a control switch which is manually operated .The control switch is connected by wire to the output of the battery. The control switch has ON/OFF mechanism which allows the current to flow when needed.
Figure 5
DISADVANTAGES
Maintenance will be very difficult
Might cause collision
1.6.2 CRANKSHAFT MECHANISM
The crankshaft is a mechanism that transforms rotary movement into linear movement, or vice versa. For example, the motion of the pistons in the engine of a car is linear (they go up and down). But the motion of the wheels has to be rotary. So, engineers put a crankshaft between the engine and the transmission to the wheels. The pistons of the engine move the crankshaft and the movement becomes rotary. Then the rotary movement goes past the clutch and the gear box all the way to the wheel.
Figure 6
DISADVANTAGES
Crank-shafts are required to be mounted on bearings which creates balancing problem.
Mechanical vibrations which in turn damage the bearings.
As bearings are of sliding type, any occurrence of variable load( which is bit obvious in case of vehicles) leads to balancing problem
1.6.3 WORKING OF RACK-PINION MECHANISM
While moving, the vehicles possess some Potential Energy due to its weight and it is being wasted. This kinetic energy can be utilized to produce power by using a special arrangement called POWER HUMP. It is an Electro-Mechanical unit. It utilizes both mechanical technologies and electrical techniques for the power generation and its storage. POWER HUMP is a dome like device likely to be speed breaker. Whenever the vehicle is allowed to pass over the dome it gets pressed downwards then the springs are attached to the dome and are compressed and the rack which is attached to the bottom of the dome moves downward in reciprocating motion. Since the rack has teeth connected to gears, there exists conversion of reciprocating motion of rack into rotary motion of gears but the two gears rotate in opposite direction.. So that the shafts will rotate with certain R.P.M. these shafts are connected through a set of gears to the dynamos, which converts the mechanical energy into electrical energy. The conversion will be proportional to traffic density.
Figure 7 Rack & pinion
The electrical output can be improved by arranging these POWER HUMPS in series. This generated power can be amplified and stored by using different electrical devices.The project is concerned with generation of electricity from speed breakers-like set up. The load acted upon the speed breaker - setup is there by transmitted to rack and pinion arrangements. Here the reciprocating motion of the speed-breaker is converted into rotary motion using the rack and pinion arrangement. The axis of the pinion is coupled with a gear.
This gear is meshed a pinion. As the power is transmitted from the gear to the pinion, the speed that is available at the gear is relatively multiplied at the rotation of the pinion. The axis of the pinion is coupled to a gear arrangement. Here we have two gears with different diameters. The gear (larger dimension) is coupled to the axis of the pinion. Hence the speed that has been multiplied at the smaller sprocket wheel is passed on to this gear of larger dimension. The pinion is meshed to the gear. So as the gear rotates at the multiplied speed of the pinion, the pinion following the gear still multiplies the speed to more intensity. Hence, although the speed due to the rotary motion achieved at the first gear is less, as the power is transmitted to gears the speed is multiplied to a higher speed. This speed is sufficient to rotate the rotor of a generator.
Figure 8 block diagram
The rotor which rotates within a static magnetic stator cuts the magnetic flux surrounding it, thus producing the electric motive force (emf). This generated emf is then sent to a bridge rectifier, where the generated AC current is converted to DC. This regulated emf is now sent to the lead-acid battery.
ADVANTAGES
Rack-Pinion assembly gives good mounting convenience
Maximum gear losses– 3 to 5%
Approximate Efficiency– 95%
CHAPTER 2
LITERATURE VIEW
2.0 HISTORY
Before electricity generation began slightly over 100 years ago, houses were lit with kerosene lamps, food was cooled in iceboxes, and rooms were warmed by wood-burning or coal-burning stoves. Direct current (DC) electricity had been used in arc lights for outdoor lighting. In the late-1800s, Nikola Tesla pioneered the generation, transmission, and use of alternating current (AC) electricity, which can be transmitted over much greater distances than direct current.
Electricity generation was first developed in the 1800's using Faradays dynamo generator. Almost 200 years later we are still using the same basic principles to generate electricity, only on a much larger scale. Now we are throwing some light on the very new and innovative concept i.e. GENERATING ELECTRICITY FROM A SPEED BREAKER. Producing electricity from a speed breaker is a new concept that is undergoing research.
Pakistan's installed capacity is nearly 10 per cent of China's capacity though both countries have million plus people. There is roughly 20 percent power deficit in the peak hours. Banks are burdened with loans to loss-making state-run electricity distribution firms and are unwilling to lend to new projects that do not have assured fuel supply. Pakistan has nearly 5 per cent of the world's coal reserves but lack of environmental clearances and other disputes have hindered production.
2.1 Literary survey
The Burger King on U.S. Highway, Customers pull in and out all day, and at least 100,000 cars visit the drive-thru each year. And a newly installed, mechanized speed bump(video) will both help them slow down and harvest some of that coasting energy.
Fig. 4.1 Speed Bump
The weight of a car is used to throw a lever, explains Gerard Lynch, the engineer behind the MotionPower system developed for New Energy Technologies, a Maryland-based company. "The instantaneous power is 2,000 watts at five miles-per-hour, but it's instantaneous which means some form of storage will be required
ASWATHAMAN.V,ELECTRONICS AND COMMUNICATIONENGINEERING SONA COLLEGE OF TECHNOLOGY, SALEM, INDIA
PRIYADHARSHINI.M, ELECTRONICS AND COMMUNICATIONENGINEERING
SONA COLLEGE OF TECHNOLOGY,SALEM, INDIA.
This paper attempts to show how energy can be tapped and used at a commonly used system- the road speed breakers. The number of vehicles passing over the speed breaker in roads is increasing day by day. A large amount of energy is wasted at the speed breakers through the dissipation of heat and also through friction, every time a vehicle passes over it. There is great possibility of tapping this energy and generating power by making the speed-breaker as a power generation unit. The generated power can be used for the lamps, near the speed breakers. The utilization of energy is an indication of the growth of a nation. For example, the per capita energy consumption in USA is 9000 KWh (Kilo Watt hour) per year, whereas the consumption in India is 1200 KWh (Kilo Watt hour). One might conclude that to be materially rich and prosperous, a human being needs to consume more and more energy. A recent survey on the energy consumption in India had published a pathetic report that 85,000 villages in India do
not still have electricity. Supply of power in most part of the country is poor.
2.2 Main components of Our Project
Project parts
Rack
Spur gear
Fly wheel
Bearings
Shaft
Springs
Electric dynamo OR Generator
2.3 Rack
It is long rectangular round having teeth on one end. It is used to transmit the translational motion into rotational motion.
2.4 Gears
A gear is a rotating machine part having cut teeth, or cogs, which mesh with another toothed part in order to transmit torque. Two or more gears working in tandem are called a transmission and can produce a mechanical advantage through a gear ratio and thus may be considered a simple machine. Geared devices can change the speed, torque, and direction of a power source. The most common situation is for a gear to mesh with another gear, however a gear can also mesh a non-rotating toothed part, called a rack, thereby producing translation instead of rotation.
2.4.1General Terminologies of Gears
Figure 9 gear
Number of teeth, N
How many teeth a gear has, an integer. In the case of worms, it is the number of thread starts that the worm has.
Gear, wheel
The larger of two interacting gears or a gear on its own.
Pinion
The smaller of two interacting gears.
Path of contact
Path followed by the point of contact between two meshing gear teeth.
Line of action, pressure line
Line along which the force between two meshing gear teeth is directed. It has the same direction as the force vector. In general, the line of action changes from moment to moment during the period of engagement of a pair of teeth. For involute gears, however, the tooth-to-tooth force is always directed along the same line—that is, the line of action is constant. indeed the case.
Axis
Axis of revolution of the gear; center line of the shaft.
Pitch point, p
Point where the line of action crosses a line joining the two gear axes.
Pitch circle, pitch line
Circle centered on and perpendicular to the axis, and passing through the pitch point. A predefined diametral position on the gear where the circular tooth thickness, pressure angle and helix angles are defined.
Pitch diameter, d
A predefined diametral position on the gear where the circular tooth thickness, pressure angle and helix angles are defined. The standard pitch diameter is a basic dimension and cannot be measured, but is a location where other measurements are made.
Module, m
A scaling factor used in metric gears with units in millimeters whose effect is to enlarge the gear tooth size as the module increases and reduce the size as the module decreases. Module can be defined in the normal (mn), the transverse (mt), or the axial planes (ma) depending on the design approach employed and the type of gear being designed. Module is typically an input value into the gear design and is seldom calculated.
Operating pitch diameters
Diameters determined from the number of teeth and the center distance at which gears operate.
Pitch surface
In cylindrical gears, cylinder formed by projecting a pitch circle in the axial direction. More generally, the surface formed by the sum of all the pitch circles as one moves along the axis. Angle of action
Angle with vertex at the gear center, one leg on the point where mating teeth first make contact, the other leg on the point where they disengage.
Arc of action
Segment of a pitch circle subtended by the angle of action.
Pressure angle,
The complement of the angle between the direction that the teeth exert force on each other, and the line joining the centers of the two gears. For involute gears, the teeth always exert force along the line of action, which, for involute gears, is a straight line; and thus,
Outside diameter,
Diameter of the gear, measured from the tops of the teeth.
Root diameter
Diameter of the gear, measured at the base of the tooth.
Addendum, a
Radial distance from the pitch surface to the outermost point of the tooth
.
Dedendum, b
Radial distance from the depth of the tooth trough to the pitch surface.
Whole depth,
The distance from the top of the tooth to the root; it is equal to addendum plus dedendum or to 0working depth plus clearance.
Clearance
Distance between the root circle of a gear and the addendum circle of its mate.
Working depth
Depth of engagement of two gears, that is, the sum of their operating addendums.
Circular pitch, p
Distance from one face of a tooth to the corresponding face of an adjacent tooth on the same gear, measured along the pitch circle.
Diametral pitch,
Ratio of the number of teeth to the pitch diameter.Could be measured in teeth per inch or teeth per centimeter.
Base circle
In involute gears, where the tooth profile is the involute of the base circle. The radius of the base circle is somewhat smaller than that of the pitch circle.
Base pitch, normal pitch,
In involute gears, distance from one face of a tooth to the corresponding face of an adjacent tooth on the same gear, measured along the base circle.
Interference
Contact between teeth other than at the intended parts of their surfaces.
Interchangeable set
A set of gears, any of which will mate properly with any other.
2.5.2 Types of Gears
1. Spur Gears
Figure 10
Spur gears or straight-cut gears are the simplest type of gear. They consist of a cylinder or disk with the teeth projecting radially, and although they are not straight-sided in form, the edge of each tooth is straight and aligned parallel to the axis of rotation. These gears can be meshed together correctly only if they are fitted to parallel shafts.
2. Bevel Gears
Figure 11 bevel gear
Bevel gears are gears where the axes of the two shafts intersect and the tooth-bearing faces of the gears themselves are conically shaped. Bevel gears are most often mounted on shafts that are 90 degrees apart, but can be designed to work at other angles as well.
3. Helical Gears
Figure 12 helical gear
Helical or "dry fixed" gears offer a refinement over spur gears. The leading edges of the teeth are not parallel to the axis of rotation, but are set at an angle. Since the gear is curved, this angling causes the tooth shape to be a segment of a helix. Helical gears can be meshed in a parallel or crossed orientations.
4. Worm Gears
Figure 13 worm gear
A worm gear is usually meshed with a spur gear or a helical gear, which is called the gear, wheel, or worm wheel .Worm gears can be considered a species of helical gear, but its helix angle is usually somewhat large (close to 90 degrees).
2.6 Shaft: A shaft is a rotating element, which is used to transmit power from one place to another.
2.7 Bearings: A bearing is a machine element, which supports another machine element. It permits a relative motion between the contact surfaces, while carrying the load.
2.8 Fly wheel: The primary function of a fly wheel is to act as energy "Accumulator' simply it reduces the 'fluctuation' of speed.
2.9 Spring: A spring is defined as an elastic body whose function is to distort when loaded and to recover its original shape when the load is removed.
2.9.1 Types of springs
These are mainly:
Helical springs
Torsion springs
Involute spring
Conical casting laminated or leaf spring.We are using Helical compression springs.
2. 10 Generator
Electric generator is a device that converts mechanical energy to electrical energy. A generator forces electric charge (usually carried by electrons) to flow through an external electrical circuit.
Chapter #3
DESIGN WORK
We have designed main components of our project.
Rack and pinion
Helical gears
Shaft
Spring
3.1 Rack And Pinion:
Module = Pitch Circle Diameter/ Number of teeth = 117/69 = 2 mm
Pitch Circle Radius(r) = 117/2 = 58.5 mm
Addendum(a) = module = 2 mm
Addendum Circle Radius (ra) = r + addendum = 58.5 + 2 = 60.5mm
Pressure angle of pinion (Φ) = 14.5 involute
Length of path of contact = KL=OK2-OL2
= (PO+LH) 2-(OPCOS Ø) 2
= (58.5+1.6) 2-(58.5x0.93) 2
= (3612-2959) = 25.55 mm
Length of arc of contact= Length of path of contact/ cos Ø
=25.55/cos 200
=27.4mm
Minimum no.of teeth contact= Length of arc of contact/circular pitch
=27.4/( *2)
=1.8 teeth
=4 teeth = one pair
Circumference of gear = 2 R= 2x 3.14x 58.5=367mm
Length of rack = 367+233=600mm
3.2 Design of Gears
Outside Diameter (Do) = 128 mm
Number of Teeth (N) = 76
Pitch Circle Diameter (D) = Do /(1+2/N) = 155/ (1+2/76) = 124.7mm
Module = D/N = 124.7/ 76 =1.64=2 mm (approx)
Pressure angle of gear (Φ) = 20°
Diametral Pitch (P) = N/D = 76/124.6 =7= 0.6 mm
Addendum (a) = 1/P = 1/0.6 = 1.66=2 mm
Dedendum (b) = 1.157/P = 1.157/0.6 =1.92 mm
Tooth Thickness = 1.5708/ P = 1.5708 / 0.6=2.61mm
Whole Depth = 2.157/P = 2.157/0.6= 3.5 mm
Clearance = 0.157/ P = 0.157/0.6 = 0.26 mm
Center Distance = (N1 + N2)/ (2*P) = (76 + 19 )/ (2* 0.6) = 79.1mm
Working Depth = 2/P = 2/0.6= 3.33 mm
Addendum Circle Diameter = D + 2m =124.7 + 2(1.63) = 127.9 mm
Dedendum Circle Diameter = D – 2.5m = 124.7 -2.5(1.63) = 120.63 mm
3.3 GEAR MATERIALS:
The material used for the manufacture of gears depend up on the strength and service conditions like wear, noise etc. The gears may be manufacture from metallic or non metallic materials. The metallic gears with cut teeth are commercially obtained by cast iron, steel and bronze. The nonmetallic materials like wood etc cue used for reducing noise.
Cast iron widely used for gears to its good wearing properties, excellent machinabitly and easy of producing complicated shapes by casting method.
3.4 PERMISSIBLE WORKING STRESS FOR GEAR
The permissible working stress (fw) in the lewis equation depends upon the material for which as allowable static stress (f0) may be determined. The allowable static stresses is the stress at the elastic limit of the material. It is also called the basic stress. In order to accounts for the dynamic effects which becomes more severe as the pitch line velocity increases the value of working stress is reduce.
According to the Barth formula .The permissible working stress (fw = f0 x Cv)
.Where f0 = Allowable static stress
Allowable static stress for ordinary cast iron is 56
Allowable static stress for medium grade cast iron is 70
Allowable static stress for highest grade cast iron is 105
Cv = velocity factor The value's of the Cv are given as follows.
Cv = 3 / 3 + V, for ordinary cut gears operating at velocities up to
12.5m/s
= 4.5 / 4.5 + V, for care fully cut gears operating at velocities up
to 12.5 m/s = 6/6 + V, for very accurately cut and ground
metallic gears operating at velocities up to 20 m/s
= 0.75 / 0.75 + V, for precession gears cut with high accuracy and
operating velocities up to 20 m/s. [0.75 11 + V] + 0.25, for non-
metallic gears. In the above expression, V is the pitch line velocity in m/s.
Tangential load on teeth
Apply lewi's eqn
Wt = f x b x n x m x y
Where, f = Stress developed in teeth
b = Face width
M = module
Y = Lewi's form factor
= 0.175 - (0.841) /20 for 20° stub involute
= 0.13295
f = fo x Cv
Where f0 = Statical working stress carried by material
= 50 N/mm2 for ordinary grade cast iron
C v = coefficient of velocity.
= Cv=(6.1+V) / 6.1 for ordinary cut gears having peripheral velocity
below 20 m/sec.
V = πDN /60 = 3.14 X 465 X 0.124/60= 3.11m/s
Cv =(6.1+V) / 6.1=1.5
Tangential load acting on the tooth WT = f0 x Cv b x x m x y
=105 x 1.5 x 54 x 3.14 x 2x 0.139=7424 N
3.6 Dynamic load
Formula : WD= WT +W1
Tangential load WT = P/v x cs = 981 x 0.125 / 3.11 = 39.42 N
Service factor CS = 0.125 (light shock 8-10 hours per day)
W1 =increment load due to dynamic action
21x3.11 (54x413+ 28.412)
= ------------- ------------------- =144.5 N
21x 3.11 (54x413+ 28.412)
WD= WT +W1 = 39+144.5=183.5 N
Static load
WS = fe b m y
=10x5N4x3.14x2x0.1329
=471 N
WS WD so design is safe
Design of shaft
3.8 Design of Spring
CHAPTER 4
PHYSICAL MODELING
Steps:
Modeling is important phase of our project .we have completed our project using Pro _E by PTC version 5. These are steps which we have followed are describe as under.
According to our calculations we made all parts in pro-e part drawings.
Assembled gearing arrangements and shaft in pro-e assembling.
Assembled all parts and box.
Mesh the gears in mechanism block.
Showing the explode view and whole assembly.
1. Rack 2.Pinon
Figure 15 pinion Figure 14 rack
3. Box
Figure 16 box
4. Breaker 5. Dome
Figure 17 breaker Figure 18 dome
6. Gear 7. Shaft
Figure 19 gear Figure 20 shaft
8. Motor 9.Spring
Figure 21 motor Figure 22 spring
4.2 ASSEMBLING PHASE
Step 1 : Mount all gaer on shaft .
Figure 23 shaft assembly
Step 2: Assemble the gears and box
Figure 24 gear and box
Step 3: Attach the rack with pinion
Figure 25 dome and box assembly
Step 4: Attach the breaker with box.
Figure 26 breaker and box
Step 5: Explode view of whole assembley
Figure 27 explode view
Step 6: complete assembly
Figure 28 complete view
CHAPTER #5
FABRICATION SUMMARY
1. Frame:
The frame structure for the total unit is fabricated using L-Angle frames and ordinary frames. These frames are made of mild steel. They are held to proper dimensions are attached to form a unit with the help of welding.
2. Bearing:
Then the bearings which are of standard make are kept in place with their respective shafts through them and are welded to the frame structure.
Shaft:
The shafts are also made of mild steel. Hinges are used to move the speed breaker arrangement by welding it to the frame structure. These hinges are responsible for the movement of the speed breaker in an up and down motion.
Rack and pinion arrangement:
A rack having thirty-eight which is made up of mild steel is welded to the speed breaker arrangement. A pinion which is also made up of mild steel and which has Thirty six teeth is fitted on the shaft initially, and welded. This pinion tooth is exactly made to mate with the teeth of the rack...
Fly wheel :
A fly wheel that is made of cast iron is machined suitably to the precise dimensions in a lathe and is placed on the shaft with its axis coinciding with the axis of the shaft and is welded.
Generator :
A special stand arrangement is made to seat the 12v DC generator using frames. A 12v DC generator is placed within the seat and is held firm using bolts and nuts. To the shaft of the generator, a small gear made of cast iron is fixed tightly. A larger gear made out of cast iron is machined well and fitted on the shaft. The teeth on the larger gear are made to mate rightly with the smaller gear that is fitted to the generator shaft.
5.1 PARTS OF SPEED BREAKER
1. Shaft
Purpose: It is used to transmit the power and holding the gear and flywheel.
Table 1
Length
200 mm
Dia
22 mm
Material
Mild steel
Specification:
Picture
Figure 29 shaft
2. Bearing
Purpose: Used to hold the shaft and provide balance
Table 2
Size
NTN 6204
Outer dia
46 mm
Inner dia
20 mm
Width
14 mm
Specification:
Picture:
Figure 30 bearing
3. FLANGE
Purpose: It is used to hold the bearing and it is fixed in metal sheet with the help of bolts.
Table 3
Material
Mild steel
Outer dia
56 mm
inner dia
46mm
Specification:
Picture
Figure 31flange
Flywheel:
Purpose: it is used to store and provide angular momentum.
Table 4
Weight
6 &10kg
Outer Dia
132mm &300mm
Inner Dia
22 mm &22mm
Thickness
57 mm &22mm
Material
Mild steel
Specification:
Picture
Figure 32 flywheel
Metal sheet:
Purpose: It is used to hold the shaft and support the frame
Table 5
Length
450
Width
450
Thickness
4mm
No of sheet
2
Material
Mild steel
Specification:
Picture
Figure 33metal sheet
7. Spring:
Purpose: It is used to store and provide elasticity
Table 6
Diameter of Wire
2 mm
Mean Diameter of Wire
20mm
Free length
154mm
Pitch of spring
57 mm
No of spring
3
Material
Mild steel
Specification:
Picture
Figure 34 spring
Helical Gears
Purpose It is used to transmit the power from one shaft to another shaft.
Table 7
Addendum (a)
1.66 mm &2.09
Module
2 &2
Dedendum (b)
1.92 mm
Clearance
.261mm&0.284mm
Tooth Thickness
3.595 &2.85mm
Diametral Pitch (P)
.6 mm &0.55mm
Pitch dia
124.7 mm &3.39mm
Outer Dia
128 mm &38mm
Bore Dia
22 mm &22mm
No of teeth
76 &19
Material
Cost Iron
No of Gears
2
Specification:
Pictures
Figure 35
Figure 36
Rack and pinion:
It is used to convert translatory motion into rotary motion.
Table 8
Module
2
Width
19mm
Thickness
19mm
No of teeth
32
Material
Cost Iron
Teeth length
155mm
No of Rack
2
Specification:
Table 9
Addendum (a)
1.66 mm
Module
2
Dedendum (b)
1.92 mm
Clearance
.261
Tooth Thickness
3.595
Diametral Pitch (P)
.6 mm
Pitch dia
116.62mm
Outer Dia
120 mm
Bore Dia
22 mm
No of teeth
69
Material
Cost Iron
No of Gears
2
Picture:
Figure 37rack
Bolt and Nut
Table 10
Outer dia
12mm
Inner dia
11.9
Thread lenght
15mm
Type
Hexagonal
Material
Mild steel
These are used to fasten two or more metal plates. These are used for temporary joint.
Specification:
Picture
Figure 38 bolt and nut
Bushes:
Purpose: It provides an interface between two parts, damping the energy transmitted through the bushing
Table 11
Bush length
2.6 mm&
Outer diameter
2.8 mm &
Inner diameter
2.1mm &
No of bushes
5
Taper bushes
Do 32&Di 29mm
Specification :
Picture
Figure 39 bushes
Figure 40
Generator:
Purpose: It is used to generate electricity
Voltage
12 v
Type
Dc
Current
60 amp
No of pair
16
No of coil
2
Battery
Lead acid
Specification:
Picture:
Figure 41 generator
L.ANGLES
Purpose: These are used to make the frame.
Specification:
Length
600mm&450&380mm
Width
30mm
Thickness
0.5mm&1mm
Table 12
Picture:
Figure 42 L-angle
13. Bicycle Flywheel
Purpose It is assemble in pinion .it is provide free motion when rack up down
Table 13
Di
22mm
No of teeth
20
Size
0.5x0.08 inch
Specification:
Picture
Figure 43
14. Electrical Accessories
Purpose: These are used to operate and control the panel.
3Pn socket3Pn socketAmp meterAmp meterButton Button voltmetervoltmeterBulb holderBulb holder
3Pn socket
3Pn socket
Amp meter
Amp meter
Button
Button
voltmeter
voltmeter
Bulb holder
Bulb holder
Figure 44 electrical accosseries
15. Breaker
Figure 45 breaker
5.2 Operation and Assembly
Frame Dimensions ( 460X460X600 mm)
Step 1: Marking
Figure 46 marking
Step 2: Cutting with the help of gas cutter
Figure 47 cutting
Step 3: Holing with the help of gas cutter
Figure 48 holing
Step 4: Drilling
Figure 49 drilling
Step 5: Make thread inside the hole.
Figure 50 hole
Step 6 Grinding
Figure 51 grinding
Step 6: Fasten flange and bearing with the help of nut and bolt.
Figure 52 fixing
Step 7: Cutting with help of hacksaw.
Step 8: lathe machine Operations (turning, boring, facing, parting)
Figure 53 Machining
Step 9: Making keyway on both the shaft for mounting gear
Figure 54 keyway
Step 10: keyway
Figure 55 keyway
STEP 11: Gear making
Figure 56 gear making
STEP 12: Making flywheel.
Figure 57 Making flywheel
STEP 13: Making keyways on all gear .
Figure 58 working
STEP 14: Mounting gear on shafts 1.
Figure 59 Mount gear on shaft
STEP 15: Mounting gear on shafts 2.
Figure 60 Mounting flywheel and gear
STEP 16: Hinge the shaft 1 in the frame
Figure 61 hinge the shaft 1
STEP 17: Hinge the shaft 2 in the frame
Figure 62 hing the shaft 2
STEP 18: Complete mounting assembly
Figure 63 mount both shaft
STEP 17: Join the different angles to make frame with the help of welding
Figure 64 making frame
Step 18: mounting another flywheel outside the frame.
Figure 65 outer flywheel
Step 19: join the rack supports with the help of welding.
Figure 66 joining the rack
Step 20: Assemble the rack support to the frame.
Figure 67 rack supporter
Step 21: Joined the bushes for spring support with the help of welding.
Figure 68 bushes
Step 22: Joined the spring.
Figure 69 spring assembly
Step 23: paint with help of spray
Figure 70 spray
Step 24: placed the Dc generator with in seat using nut and bolts.
Figure 71 generator
Step 25: placed the breakers with in seat using nut and bolts.
.
Figure 72 placing breaker
Step 26: Cover the wooden blocks with metal sheet and paint the blocks.
Figure 73 paint the breaker
Step 27: Attached the hump with rack and pinion mechanism
Figure 74 final assembly
Step 28: paint the dome and other attachment.
Figure 75 paint full assembly
Step 29: Mount the bulb holders, voltmeter and inverter on transparent sheet and all accessories .
Figure 76 electrical assembly
5.3 WIRING DESCRIPTION
Coupled the wire of dc generator with dc holder and then these wires are coupled with the battery terminals .
Coupled the battery positive and negative with inverter (DC to AC).
Inverter input coupled with ac bulb and voltmeter.
5.3.1Circuit Diagram:
Figure 77 wire description
5.3.2 Wire coupling:
Figure 78 wire coupling
5.4 FINAL MODAL
View 1
View2
Figure 79 view 1
Chapter # 6
Result and conclusion
Energy is important part to retain the industrial production rate and also the progress of any Country. The conventional sources are reducing day by day and by the turn of century, we have to depend upon the non-conventional sources of energy. (Non-conventional sources such as solar energy, wind energy, biogas etc.)
We can also increase the growth of country by installing speed breaker in heavy traffic roads and toll plaza. We can generate electricity almost continuously by using the weight of the vehicles to produce mechanical power in the shafts by using the rack and pinion mechanism. As this method does not require any external power source and the traffic never reduces, these speed breakers are more reliable and have a greater life span.
6.2 Model calculation
The mass of a vehicle = 150Kg
Height of speed brake =10 cm
Work done=Force x Distance
where, Force = Weight of the Body = 150 x 9.81m/s = 1471.5 N
Distance travelled by the body = Height of the speed brake =10 cm
Output power= (1471.5 x 0.1)/60 = 2.452 Watts (For One pushing force)
Power developed for 1 vehicle passing over the speed
breaker arrangement for one minute = 2.452 watts
Power developed for one hour =147.12 watts
Power developed for one day = 3.531 kw
Power developed for one month = 105.9 kw
Power developed for one year = 1271.16 kw
6.3 Actual Calculation
Generated output voltage in one pushing force of speed breaker = 6.8v
Current in the circuit in one pushing force of speed breaker = 0.30 amps
As per ohm's law
Power developed for one push= V*I = 6.8 *0.31
p= 2.1 w
Power developed for one hour = 60 * 2.41 = 144.6 watts
Power developed for one day = 24 * 146.4 = 3.47 kw
Power developed for one month = 30 * 3513.1 = 104.118 kw
Power developed for one year = 12 * 105.408 = 1249.3 kw
6.4 Conclusion
For 100 bikes in a day Power generated = 2.1 * 100 = 210.1 watts
Percentage Error = (2.45 – 2.1)/ 2.1 * 100 = 16.2 %
We can store the electricity produce from speed breaker in battery and then we can use it according to desire.
6.5 What We Achieve ?
Our Actual task is to produce 12 volts which is our basically splendid first achievement with the help of speed breaker .
Our extra work is to produce 220 volts with the help of inverter which is basically our best achievement.
6.6 Future scope of this project
Future work would consist of a redesign of this model to see exactly how much data we may be missing with the assumption that we made with low price, weight and capacity. Despite all the assumptions, we still have realized that this product can be very marketable and that the demand is extremely large which means this is a viable design that will yield a high return on an investment.
Such speed breakers can be designed for heavy vehicles, thus increasing input torque and ultimately output of generator.
More suitable and compact mechanisms to enhance efficiency.
Various government departments can take up an initiative to implement these power humps on a large scale.
These can be mainly used at toll booths , approaching traffic signals , highways where vehicles move 24 x 7 etc…
This has a huge scope everywhere provides the resources are channelled well.
Chapter # 7
References
( EVERY SPEED BREAKER IS NOW A SOURCE OF POWER)
EVERY SPEED BREAKER IS NOW A SOURCE OF POWER
2010 International Conference on Biology, Environment and Chemistry
IPCBEE vol.1 (2011) © (2011) IACSIT Press, Singapore
CP Racks & Pinions
Catalog Numbers of KHK stock gears
PRODUCE ELECTRICITY BY THE USE OF SPEED BREAKERS
Journal of Engineering Research and Studies E-ISSN 0976-7916
JERS/Vol.II/ Issue I/April-June, 2011/163-165
Speed Bumps Harvest Electricity from Moving Cars by Sarah Parsons, 09/08/09
Design of Machine Elements by R.S Khurmi
Mechanics of Materials by Shigley
Booklet of ASME standards for selection of bearings
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