Speed Breaker Power Generation

Generation of Electricity through Speed Breaker Mechanism
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GENERATION OF ELECTRICITY THROUGH SPEED BREAKER

MECHANISM
Department Of Mechanical Engineering

RACHNA COLLEGE OF ENGINEERING AND TECHNOLOGY, GUJRANWALA
(A Constituent College of UET Lahore.)
SESSION 2010
Submitted By
Samiullah Kakar
(2010-ME-442)
Project Supervisor
Engr. Muhammad Qasim Tatla
Assistant Professor, Department of Mechanical Engineering
RACHNA COLLEGE OF ENGINEERING AND TECHNOLOGY, GUJRANWALA.
As partial fulfillment of the requirements for the
Bachelors Degree
In
MECHANICAL ENGINEERING
This report is submitted to
Department of Mechanical Engineering,
Rachna College of Engineering and Technology, Gujranwala
This is declaring that work submitted in this report is my own, and any work that is not mine has
been quoted and acknowledged in the references.
Approved On------------------------------
Internal Examiner: Engr. Muhammad Qasim Tatla
Signature: -----------------------------------------
External Examiner:
Signature: -------------------------------------------
Department of Mechanical Engineering,
Rachna College of Engineering and Technology, Gujranwala
(A Constituent College of UET, Lahore)
Dedication
I dedicate this work to my beloved parents for

always supporting me, because they are the
driving force in my life and career. Without their
love, none of this would matter. Throughout my
life, they have actively supported me in my
determination to find and realize my potential,
and to make this contribution to our world.
Acknowledgements
Thanks to ALLAH ALMIGHTY that enabled me to work in this project because without His approval
man can do nothing. After almighty Allah to his prophet, HAZRAT MUHAMMAD (PBUH), the most
perfect an exalted forever source of guidance and knowledge humanity as a whole.
There are a number of people without whom this project might not have been written, and to whom I am
greatly indebted.
I will forever be thankful to my advisors, Engr. Muhammad Qasim Tatla for supporting me during this
study. He has provided insightful discussions about the research. His support and penetrates has allowed
me to complete one of my many life goals. I would also thankful to our Honorable teacher Engr.
Nouman Javed for guiding me on all my work and project. I value the guidance that was giving to me.
Regards
Samiullah Kakar
Contents
ABSTRACT
chapter number 1
INTRODUCTION OF THE PROJECT
1. INTRODUCTION 4
2. SCOPE OF THE PROJECT
chapter number 2
DEMONSTRATION OF THE PROJECT
1. WORKING PRINCIPLE 6
2. BLOCK DIAGRAM 7
chapter number 3
CMODELLING, SIMULATION AND RESULTS8
1. FABRICATION DETAILS 9
2. FABRICATION MODEL SHOWING INNER PARTS
3. MATERIALS USED 10
4. SPECIFICATIONS 10
5. ADVANTAGES
11
6. DISADVANTAGE 11
chapter number 4
ACCESSORIES REQUIRED
1. RACK AND PINION
12
13
2. SPROCKET 14
3. DRIVE ARRANGEMENTS
14
4. BEST ARRANGEMENTS
15
5. OTHER ACCEPTABLE ARRANGEMENTS 15
6. LEAST RECOMMENDED ARRANGEMENTS
16
7. SPROCKET DIMENSIONAL SPECIFICATIONS 17
chapter number 5
CHAIN DRIVES
19
1. Chain Drives
20
2. Chain Drive Design
3. Vibrations
22
23
4. Avoiding vibration
24
5. Chain Types 24
6. Chain Failures
26
chapter number 6
WHEELS AND SPRINGS 28
1. Freewheel
29
2. Flywheel
30
3. Springs 32
chapter number 7
DESIGN PARAMETER`S AND LIMITATION 38
1. OUTPUT POWER CALCULATIONS 39
2. DESIGN SPECIFICATIONS
41
3. SPROCKET WHEEL AND CHAIN
4. SPRINGS
41
5. SPUR GEARS
41
COST ANALYSIS
42
REFERENCES 46
41
ABSTRACT
Man in his lifetime, uses energy in one form or the other. In fact
whatever happens in nature, results, out of the conversion of energy in
one form or the other. The blowing of the wind, the formation of the
clouds and the flow of water are a few examples that stand testimony
to this fact. The extensive usage of energy has resulted in an energy
crisis, and there is a need to develop methods of optimal utilization,
which will not only ease the crisis but also preserve the environment.
Energy conservation is the cheapest new source of energy. This project
attempts to show how energy can be tapped and used at a commonly
used system, the generation of electricity through the speed breaker
mechanism. Generation of electricity through the speed breaker
mechanism is one of the most recent power generation concepts. This
device converts the kinetic energy of the vehicles into electric energy
by installing movable speed breaker on the road, it takes the stroke
motion of the vehicles and converts it to the rotary motion by rack and
pinion mechanism and it generates the electricity. This project also
explains clearly, the working principle of the designed system, its
practical implementation, and its advantages. Design of each
component has been carried out using standard procedures, and the
components have been fabricated and assembled. A similar model of
the system has been modeled using AutoCAD 2007. Practical testing of
the system has been done with different loads at different speeds. The
utilization of energy is an indication of the growth of a nation. One
might conclude that to be materially rich and prosperous, a human

being needs to consume more and more energy. And this project is
best source of energy that we get in day to day life.
GENERATION OF
ELECTRICITY THROUGH
SPEED BREAKER
MECHANISM
Chapter Number 1
Introduction of the
project
INTRODUCTION
SCOPE OF THE PROJECT
1. INTRODUCTION:This project 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 speedbreakers. In this model we show that how we can generate a voltage
from the busy traffic. Conversion of the mechanical energy into
electrical energy is widely used concept. Its a mechanism to generate
power by converting the potential energy generated by a vehicle going
up on a speed breaker into rotational energy. We have used that simple
concept to the project.
2. SCOPE OF THE PROJECT:The utilization of energy is an indication of the growth of a nation. For
example, World average per capita electricity consumption is 2730
kWh compared to Pakistans per capita electricity consumption of 451
kWh. Pakistan has an installed electricity generation capacity of
22,797MW. The average demand is 17,000MW and the shortfall is
between 4,000 and 5,000MW. One might conclude that to be materially
rich and prosperous, a human being needs to consume more and more
energy.
Pakistan is facing serious energy crisis at this time .Pakistan as third

world developing country is lot affected by this energy crisis in the
world .The major issue is electric crisis which is known as load
shedding Pakistans small manufacturing markets are lot affected by
the rise of energy prices.
By just placing a unit like the Power Generation Unit from Speed
Breakers, so much of energy can be tapped. This energy can be used
for the lights on the either sides of the Roads and thus much power
that is consumed by these lights can be utilized to send power to these
villages.
Chapter Number 2
Demonstration of the
Project
WORKING PRINCIPLE
BLOCK DIAGRAM
1 WORKING PRINCIPLE: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 the sprocket arrangement. The sprocket
arrangement is made of two sprockets. One of larger size and the other
of smaller size (free wheel). Both the sprockets are connected by
means of a chain which serves in transmitting power from the larger
sprocket to the smaller sprocket. As the power is transmitted from the
larger sprocket to the smaller sprocket, the speed that is available at
the larger sprocket is relatively multiplied at the rotation of the smaller
sprocket. The axis of the smaller sprocket is coupled to a fly wheel. The
fly wheel is coupled to the shaft at axis of the smaller sprocket. Hence
the speed that has been multiplied at the smaller sprocket wheel is
passed on to this fly wheel of larger dimension. The smaller sprocket is
coupled to the larger fly wheel. So as the larger fly wheel rotates at the
multiplied speed of the smaller sprocket, the smaller sprocket following
the larger sprocket still multiplies the speed to more intensity. Hence,
although the speed due to the rotary motion achieved at the larger
sprocket wheel is less, as the power is transmitted to fly wheel, finally
the speed is multiplied to a higher speed. This speed which is sufficient
to rotate a shaft connected to generator. The rotor (shaft) rotates the
generator. The generator produces the DC current. This DC current is
now sent to the storage battery where it is stored during the day time.
This current is then utilized in the night time for lighting purposes on
the either sides of the road to a considerable distance.
2 BLOCK DIAGRAM:-
SPEED BRAKER
RACK & PINION
Fly wheel
AND CHAIN
ARRANGE
SPROCKET
MENT
ARRANGEMENT
GENERATOR
BATTERY
INVERTER
STREET
LIGHTS
Chapter Number 3
Modeling, Simulation
and
Results
1. FABRICATION DETAILS
2. FABRICATION MODEL SHOWING INNER
PARTS
3. MATERIALS USED
4. SPECIFICATIONS
5. ADVANTAGES
6. DISADVANTAGE
1. FABRICATION DETAILS: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. 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. 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. A rack which are 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. A bicycle sprocket and chain
arrangement of standard make is fitted with the larger sprocket on the
top shaft and its smaller sprocket on the bottom shaft. The sprocket
wheels are welded to the shafts. 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. 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.
2. FABRICATION MODEL SHOWING INNER

PARTS:Wires are connected to the terminals of the DC generator and its other
ends are connected to a Lead-Acid battery. Another wire is taken from
these points on the battery and its other ends are connected to the
positive and negative terminal of an inverter. An output wire from the
inverter is sent to the light.
3. MATERIALS USED:
Rack
Mild steel
Pinion
Mild Iron
Sprocket wheelsMild steel
Chain
Mild steel
Spur gears
Cast Iron
Springs
Mild steel
Shaft
Mild steel
Speed breaker - Mild steel
SPECIFICATIONS:Generator - 12v DC generator
Battery
- lead acid battery
Inverter
250 w AC inverter
10
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.
No consumption of any fossil fuel which is non-renewable source of energy.
Uninterrupted power generation during day and night.
Maximum utilization of energy.
Load to the piston cylinder arrangement is freely got by movement of vehicles.
No fuel storage is required.
.It will work with light weight and heavy vehicle
DISADVANTAGE:We have to check mechanism from time to time
It can get rusted in rainy season.
11
Chapter Number 4
Rack, Pinion and

Sprocket
1. RACK AND PINION

2. SPROCKET
3. DRIVE ARRANGEMENTS
4. BEST ARRANGEMENTS
5. OTHER ACCEPTABLE ARRANGEMENTS

6. LEAST RECOMMENDED ARRANGEMENTS
7. SPROCKET DIMENSIONAL SPECIFICATIONS
12
RACK AND PINION:A rack and pinion gears system is composed of two gears. The normal round gear
is the pinion gear and the straight or flat gear is the rack.
A rack and pinion is a type of linear actuator that comprises a pair of

gears which convert rotational motion into linear motion. The circular
pinion engages teeth on a linear "gear" bar which is called the rack.
Rotational motion applied to the pinion will cause the rack to move to the side, up
to the limit of its travel.
For example, in a rack railway, the rotation of a pinion mounted on a locomotive or

a railcar engages a rack between the rails and pulls a train along a steep slope.
The rack and pinion is also used to convert between rotary and linear
motion. The rack is the flat, toothed part, and the pinion is the gear.
Rack and pinion can convert from rotary to linear of from linear to
rotary motion.
It converts the linear motion of the speed breaker into the circular motion needed
to turn the shaft.
13
2. SPROCKET:A sprocket or sprocket-wheel is a profiled wheel with teeth or cogs that

mesh with a chain, track or other perforated or indented material. The
name "sprocket" applies generally to any wheel upon which are radial
projections that engage a chain passing
over it. It is distinguished from a gear in that sprockets are never

meshed together directly, and differs from a pulley in that sprockets
have teeth and pulleys are smooth. The word "sprockets" may also be
used to refer to the teeth on the wheel.
Sprockets are used in bicycles, motorcycles, cars, tracked vehicles,

chainsaws and other machinery either to transmit rotary motion between
two shafts where gears are
unsuitable or to impart linear motion to a track, tape etc. Perhaps the

most common form of sprocket may be found in the bicycle, in which
the pedal shaft carries a large sprocket-wheel, which drives a chain,
which, in turn, drives a small sprocket on the axle of the rear wheel.
Early automobiles were also largely driven by sprocket and chain
mechanism, a practice largely copied from bicycles.
Sprockets are of various designs, a maximum of efficiency being

claimed for each by its originator. Sprockets typically do not have a
flange. Some sprockets used with timing belts have flanges to keep the
timing belt centered. Sprockets and chains are also used for power
transmission from one shaft to another where slippage is not
admissible, sprocket chains being used instead of belts or ropes and
sprocket-wheels instead of pulleys. They can be run at high speed and

some forms of chain are so constructed as to be noiseless even at high
speed.
3.
DRIVE ARRANGEMENTS:-
Relative position of sprockets in drives should receive careful

consideration. Satisfactory operation can be secured with the
centerline of the drive at any angle to the horizontal, if proper
consideration is given. Certain arrangements require less attention and
care than others are, therefore, less apt to cause trouble. Various
arrangements are illustrated in the diagrams. The direction of rotation
of the drive sprocket is indicated.
14
4. BEST ARRANGEMENTS:Arrangements considered good practice are illustrated in Figs. 1, 2, 3,

and 4. The direction of rotation of the drive sprockets in Figs. 1 and 4
can be reversed.
5. OTHER ACCEPTABLE ARRANGEMENTS:If none of the above arrangements can be followed, an attempt should
be made to use an arrangement as illustrated in Figs. 5, 6, and 7.
15
When the large sprocket is directly above the small sprocket, Fig. 8, a
drive cannot operate with much chain slack. As the chain wears, shaftcenter distance must be adjusted or an idler be placed against the
outside of the slack strand (near the small sprocket) to adjust slack and
keep the chain in proper contact with the small sprocket. With the drive
slightly inclined, Fig. 5, less care will be required, because the weight
of the slack chain strand helps to maintain better contact between the
chain and the sprockets. Where center distances is short, or drives
nearly horizontal, the slack should be in the bottom strand, especially
where take-up adjustment is limited, Fig. 6 rather than Fig. 9. An
accumulation of slack in the top strand may allow the chain to be
pinched between the sprockets, Fig. 9. When small sprockets are used
on horizontal drives, it is better to have the slack strand on the bottom,
Fig. 7, rather than on the top, Fig. 10. Otherwise, with the appreciable
amount of slack, the strands may strike each other.
6. LEAST RECOMMENDED ARRANGEMENTS:-
16
American sprocket manufacturers have adopted 4 specific types of

sprocket Construction styles as American Standards. In addition to the
standard sprockets, Special sprockets may be available in the same
styles.
Style A - Flat sprocket with no hub extension either side.
Style B - Sprocket with hub extension one side.
Style C - Sprocket with hub extension both sides.
Style D - Sprocket with a detachable bolt on hub attached to a plate.
SPROCKET DIMENSIONAL SPECIFICATIONS:Bottom Diameter (B.D.):
The diameter of a circle tangent to the bottoms of the tooth spaces.
Caliper Diameter:
Since the bottom diameter of a sprocket with odd number of teeth

cannot be measured directly, caliper diameters are the measurement
across the tooth spaces nearly opposite.
17
c. Pitch Diameter (P.D.):
The diameter across to the pitch circle which is the circle Followed by
the centers of the chain pins as the sprocket revolves in mesh with the
chain.
PD =
PITCH
SIN (180/Nt)
d. Outside Diameter (O.D.):
The measurement from the tip of the sprocket tooth across to the
corresponding point directly across the sprocket. It is comparatively
unimportant as the tooth length is not vital to proper meshing with the
chain. The outside diameter may vary depending on type of cutter
used.
OD = (Pitch) (.6 + COT [180 / Nt])
e. Hub Diameter (HOD):
That distance across the hub from one side to another. This diameter
must not exceed the calculated diameter of the inside of the chain side
bars.
f. Maximum Sprocket:
Maximum Sprocket Bore is determined by the required Bore hub wall

thickness for proper strength. Allowance must be made for keyway and
setscrews.
g. Face Width:
Face width is limited in its maximum dimension to allow proper

clearance to provide for chain engagement and disengagement. The
minimum width is limited to provide the proper strength to carry the
imposed loads.
h. Length thru Bore:
Length Thru Bore (or L.T.B.) must be sufficient to allow (LTB) a long
enough key to withstand the torque transmitted by the shaft. This also
assures stability of the sprocket on the shaft.
18
Chapter Number 5
Chain Drives
1. Chain Drives
2. Chain Drive Design
3. Vibrations
4. Avoiding vibration
5. Chain Types
6. Chain Failures
19
CHAIN DRIVES:
Chain drives are a means of transmitting power like gears, shafts and
belt drives
Characteristics
High axial stiffness
Low bending stiffness
High efficiency
Relatively cheap
History and development
First belt drives: China c100 BC
First chain drives: Roman c200 AD
20
Leonardo DaVinci: sketch of leaf type chain c1500 AD many

similarities to modern chains.
Galle chains: 19
bushes).
th
century first mass produced roller chains (no
Hans Renold (Switzerland) 1880 invented modern bush roller chain
Bush Roller Chains:
Parts of a bush roller chain,
21
Terminology:
Manufacture:
Bushes and pins: cold drawn, cropped, turned/ground, case hardened,

ground again and shot peened.
Side-plates are stamped from plate.
Assembly
Pins and bushes are press-fitted into appropriate side plates.
2. CHAIN DRIVE DESIGN:Chain length and center distance:
Chain must contain even integer number of links
Hence cannot pick an arbitrary center distance and chain pitch
Nearest chain lengths (in pitches) for a contemplated center distance,
CC
, are calculated by empirical formulae like (for a two sprocket system:
Where N1and N2 is the numbers of teeth on sprockets and P is the

chain pitch.
The result of which should be ROUNDED UP to the next even number to

calculate the actual center separation, CA:
Inertial force in chain:
In addition to the tension required to transmit power, chain tension

also provides centripetal force to move links around sprockets
The extra inertial force, Fcf, is given by:
Vibrations:
Chain between sprockets can vibrate like a string
Basic
equation for natural frequency, fn, of taught string
Where F is the tension, m is the mass per unit length, L is the length
and k is the mode number
23
For tight side of chain there are typically ranges of resonant

frequencies given by:
Where,
Fc is the tight span tension (excluding inertial contribution)
Avoiding vibration:To avoid the chain resonating, need to avoid having sources of excitation with
frequencies near possible resonant frequencies
Obvious source is impact of sprocket teeth on chain
Frequency of these occurs at:
Where is the sprocket rotation speed and N is the number of teeth.
Chain Types:Transmission chains

Chains to transmit rotary power between shafts
Bush roller chains are transmission chains
For more power capacity, multi-strand transmission chains are used
24
Conveyor chain
Rollers sit proud of links and can roll along supporting surface.
Can be used for transporting materials, as roller scan support

weight.
Can also be used just to support weight of chain if transmitting

power over long distances.
Inverted tooth (or silent) chain

Sprocket teeth mesh with shaped links instead of rollers on chain
Joints between links use rolling rather than sliding contact
Profile of links are more like involute gear teeth Overall effect is to reduce
noise
25
4) Leaf (or lifting) chain

Designed for lifting rather (than power transmission)
Do not have to mesh with sprockets, hence no rollers
Therefore can narrower than roller chain with equivalent strength
Example: fork-lift truck
Chain Failures:Failures caused by poor selection

Overload
Failure of side plates due to cyclic load fatigue
Failure of bush or roller due to impact fatigue
Above failures can still occur due to poor installation or

maintenance
Misalignment
Incorrect or failed lubrication system
If correct chain is selected, installed and maintained

the overall life is determined by wear
Causes and effects of chain wear
Caused by material removal as chain components slide relative to each other
Effect of wear is to cause the chain to gradually elongate
26
As pitch increases, chain sits at larger and large radius on sprockets
Limit is when chain jumps over sprocket teeth
Empirical extension limits are
2 % for sprockets with less than 200 teeth
200/N % for sprockets with more than 200 teeth
Wear life
Typically 15,000 hours for any power, chain or sprocket size if correctly selected,
installed and maintained.
27
Chapter Number 6
Wheels and springs
1. Freewheel
2. Flywheel
3. Springs
28
1. FREEWHEEL:A freewheels consists of either a single sprocket or a set of sprockets

mounted on a body which contains an internal ratcheting mechanism
and mounts on a threaded hub.
Mechanics:
The simplest freewheel device consists of two saw-toothed, springloaded discs pressing against each other with the toothed sides
together, somewhat like a ratchet. Rotating in one direction, the saw
teeth of the drive disc lock with the teeth of the driven disc, making it
rotate at the same speed. If the drive disc slows down or stops
rotating, the teeth of the driven disc slip over the drive disc teeth and
continue rotating, producing a characteristic clicking sound
proportionate to the speed difference of the driven gear relative to that
of the (slower) driving gear.
A more sophisticated and rugged design has spring-loaded steel rollers

inside a driven cylinder. Rotating in one direction, the rollers lock with
the cylinder making it rotate in unison. Rotating slower, or in the other
direction, the steel rollers just slip inside the cylinder.
Advantages:
Free wheel mechanism acts as an automatic clutch, making it possible to

change gears in a manual gearbox, either up- or downshifting, without
depressing the clutch pedal, limiting the use of the manual clutch to
starting from standstill or stopping.
Disadvantages:
The major disadvantage of the multiple sprocket freewheel design is
that the drive-side bearing is located inboard of the free wheel, and as
sprockets were added over time, moved the bearing farther from the
drive-side axle support. This resulted in more flexing stress is placed
on the axle which can bend or even break.
29
2. FLYWHEEL:A flywheel is a rotating mechanical device that is used to store rotational

energy. Flywheels have a significant moment of inertia and thus resist
changes in rotational speed. The amount of energy stored in a flywheel is
proportional to the square of
its rotational speed. Energy is transferred to a flywheel by applying

torque to it, thereby increasing its rotational speed, and hence its
stored energy. Conversely, a flywheel releases
stored energy by applying torque to a mechanical load, thereby

decreasing its rotational speed.
Energy Stored in a Flywheel:

A flywheel is shown in Fig. when a flywheel absorbs energy its speed
increases and when it gives up energy its speed decreases.
Let
m= Mass of the flywheel in kg,
k = Radius of gyration of the flywheel in meters,
I = Mass moment of inertia of the flywheel about the axis of rotation in

2
kgm =m.k ,
N1and N2 = Maximum and minimum speeds during the cycle in r.p.m,
1and 2 = Maximum and minimum angular speeds during the cycle in

rad / s,
N= Mean speed during the cycle in r.p.m.
30
The radius of gyration (k) may be taken equal to the mean radius of
the rim (R), because the thickness of rim is very small as compared to
the diameter of rim. Therefore substituting k= R in equation (ii), we
have
E=m.R . .CS= m.v .CS ( v= .R)
From this expression, the mass of the flywheel rim may be determined.
Notes: 1.In the above expression, only the mass moment of inertia of
the rim is considered and the mass moment of inertia of the hub and
arms is neglected. This is due to the fact that the major portion of
weight of the flywheel is in the rim and a small portion is in the hub
and arms. Also the hub and arms are nearer to the axis of rotation,
therefore the moment of inertia of the hub and arms is very small.
The density of cast iron may be taken as 7260 kg / m and for cast
3
steel, it may taken as 7800 kg / m .
The mass of the flywheel rim is given by
m= Volume Density = 2 R A
31
From this expression, we may find the value of the cross-sectional area
of the rim. Assuming the cross-section of the rim to be rectangular,
then
A=b t
where
b= Width of the rim, and
t = Thickness of the rim.
Knowing the ratio of b/twhich is usually taken as 2, we may find the

width and thickness of rim.
4. When the flywheel is to be used as a pulley, then the width of rim

should be taken 20 to 40 mm greater than the width of belt.
3. SPRINGS: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. The
various important applications of springs are as follows :
To cushion, absorb or control energy due to either shock or vibration as in

car springs, railway buffers, air-craft landing gears, shock absorbers and
vibration dampers.
To apply forces, as in brakes, clutches and springloaded valves.
To control motion by maintaining contact between two elements as in

cams and followers.
To measure forces, as in spring balances and engine indicators.
To store energy, as in watches, toys, etc.
32
Types of Springs:
Though there are many types of the springs, yet the following,
according to their shape, are important from the subject point of view.
Helical springs:
The helical springs are made up of a wire coiled in the form of a helix
and is primarily intended for compressive or tensile loads. The crosssection of the wire from which the spring is made may be circular,
square or rectangular. The two forms of helical springs are compression
helical springas shown in Fig. (a) and tension helical spring as shown in
Fig. (b).
Advantages:
These are easy to manufacture.
These are available in wide range.
These are reliable.
These have constant spring rate.
Their performance can be predicted more accurately.
Their characteristics can be varied by changing dimensions.
33
Conical and volute springs:

The conical and volute springs, as shown in Fig. are used in special
applications where a telescoping spring or a spring with a spring rate
that increases with the load is desired. The conical spring, as shown in
Fig.(a), is wound with a uniform pitch whereas the volute springs, as
shown in Fig. (b), are wound in the form of parabolic with constant
pitch and lead angles. The springs may be made either partially or
completely telescoping. This characteristic is sometimes utilized in
vibration problems where springs are used to support a body that has a
varying mass.
34
Torsion springs:
These springs may be of helical or spiral type as shown in Fig. The
helical type may be used only in applications where the load tends to
wind up the spring and are used in various electrical mechanisms. The
spiral type is also used where the load tends to increase the number of
coils and when made of flat strip are used in watches and clocks.
The major stresses produced in torsion springs are tensile and

compressive due to bending.
Laminated or leaf springs:

The laminated or leaf spring (also known as flat spring or carriage
spring) consists of a number of flat plates (known as leaves) of varying
lengths held together by means of clamps and bolts, as shown in Fig.
These are mostly used in automobiles.
The major stresses produced in leaf springs are tensile and

compressive stresses.
Laminated or leaf springs.
Disc or Bellevile springs.
35
Values of allowable shear stress, Modulus of elasticity and Modulus of

rigidity for various spring materials.
36
Standard Size of Spring Wire:

Standard wire gauge (SWG) number and corresponding diameter of
spring wire.
37
Chapter Number 7
Design Parameter`s and

Limitations
1.
OUTPUT POWER CALCULATIONS
2.
DESIGN SPECIFICATIONS
3.
SPROCKET WHEEL AND CHAIN
4.
SPRINGSSPUR GEARS
38
1. OUTPUT POWER CALCULATIONS:Let us consider,
The mass of a vehicle moving over the speed breaker =

10Kg (Approximately)
Height of speed brake
=
10 cm
Work done
=
Force x Distance
Here,
Force
= Weight of the Body
= 10 Kg x 9.81
= 98.1 N
Distance traveled by the body = Height of the speed brake = 10 cm
Output power = Work done/Sec
(89.1 x 0.10)/60
0.1485 Watts (For One pushing force)
Power developed for 1 vehicle passing over the speed breaker

arrangement for one minute
0.1485 watts
8.91 watts
Power developed for 60 minutes (1 hr)
Power developed for 24 hours
39
213.84watts
Velocity Ratio of Chain Drives:

The velocity ratio of a chain drive is given by
. .= 1
N1= Speed of rotation of smaller sprocket in r.p.m.,
N2= Speed of rotation of larger sprocket in r.p.m.,
T1= Number of teeth on the smaller sprocket, and
T2= Number of teeth on the larger sprocket.

. .=
=2
. .=
36
19
= 1.894
Experimentally,
Revolution
Revolution of shaft by one push:
Using tachometer, 100 rpm =1.666rps
Torque:
Torque produce in on push:
=
60
0.148 60
= 0.851
2 1.666
40
2. DESIGN SPECIFICATIONS:
SHAFT (DIA)
= 65 mm
Diameter of flywheel
= 540 mm
Thickness of flywheel
= 20 mm
SPROCKET WHEEL AND CHAIN:No of teeth on large sprocket =36
No of teeth on small sprocket =19
Dia of large sprocket

=460 mm

Dia of small sprocket
= 230 mm
Length of chain
=1620 mm
Optimum centre distance

= 560 mm
4. SPRINGS:
Diameter of wire
= 2 mm
Mean dia of coil

= 12 mm
Free length of spring

= 300mm
5. SPUR GEARS:-
No Of Teeth On Rack
= 36
Rack Length
= 230mm
No Of Teeth On Pinion
=36
Diameter Of Pinion Gear

=270mm
Thickness of pinion gear

=20mm
Length of speed breaker

=290mm
Width of speed breaker

=220mm
Height of speed breaker

=130mm
41
COST ANALYSIS:Cost:
It is defined as the amount of expenditure occurred in bringing out a

product.
Cost is expressed along with the atom viscose of bicycle axle Rs.15/per axle cost of bearing Rs.150/.Bearing.
Cost of Elements:
The different cost is placed in three categories.
Material Cost
Labor Cost
Other Expenses
Material Cost:
It is the cost on the material, which is converted into product. This is of

two types:
Direct Material Cost
It is cost of all those materials which when worked upon become the
integral part of the product. For example lathe bed casting when
machined, heat treated and grounded becomes a lathe bed.
Indirect Material Cost
All those materials, which are consumed during manufacturing for

processing a product, but do not become part of product. For example
electric energy, cutting oil, grease, water and cotton waste.
Prime Cost
This is also known as direct cost. Prime Cost = direct material cost +
direct labor cost and expenses
Factory Cost
This is also known as factory cost. Factory cost = prime cost + factory
expenses.
42
Office Cost
This is also known as production office cost = factory cost +

administrative expenses + all and the expenses.
Total Office
This is also known as selling cost. Total cost = office cost + selling and
distribution expenses
Selling price of product
Selling cost = total cost + profit loss
Brake Even Chart:
This is graphical illustration to show loss and profit region. This type is
deciding the no of units to be made at which three is neither any loss nor
any profit. It is arrived it a following
Fixed Cost:
This is the cost, independent of product. This cost is three even if the
product is nil.
Labor cost
It is the labor which converts raw material into product which tools and
machines and hence the cost over the labor
Direct Labor cost
All the labors are working on the machines and material who can be
identified with the product, are called direct labor and hence cost over
them. For example, a lathe operator, a milling man.
Indirect labor cost
All the labors that help in manufacturing cycle but cannot be identified
directly with a particular product and hence cost over them. For
example, Sweepers, gate keepers, rigors, store keepers etc.
Other Expenses
All those expenses not covered under labor and material cost fall under
this category. They are also of two types.
43
Direct expenses
All those expense, which can be assigned to a particular job, are placed
in this category. This will include the following.
Expenses incurred in preparing design, drawing and process sheet.
Cost of jobs, fixtures is any made / hired for the job.
Patterns used for the mold.
Any consultation fee paid for the job.
Indirect expenses
All other expenses left out for above. They make a major part of the
cost. These expenses are of following type.
Factory Expenses
This is also known as factory over heads, factory on cost on work on

cost.
Administrative expenses
This is also known as office on cost.
Selling expenses
Distribution expenses
R & D expenses
Selling price of product, It can be calculated as follows:
44
Selling price of pipe bending machine:
Prime Cost:
Prime cost = material cost + labor cost + other cost. =Rs,4500/.
Bearing, cutting tool, screw etc. = Rs500/.
Material cost = Rs3500.
Labor cost = 15hrs (no of machine operators * Rs50 per hour)
15 hour (5* Rs50 per hour)
500 Rs.
Other expenses:
= manufacturing process (painting + machines and energy consumed)

Other expenses = 500 + 15hours 10Rs/hour
= 650/.
Factory Cost:
Factory cost = prime cost + factory expenses = 4500 + 500 = Rs5000.
Total cost:
Total cost = office cost + selling cost and distribution cost =Rs 10150.
Selling cost:
Selling cost = total cost + profit lose.
10150 + (10 % * total cost)
10150 + (10 * 10150/100) = Rs. 11155
By adding the general sales taxes = selling cost + 16% = 11155 +

16% = Rs. 12939
Selling Cost = Rs. 12939
45
REFERENCES:-
I. Department of Mechanical Engineering Queens Building,

University of Bristol, Bristol, BS8 1TR, UK
A Textbook of Machine Design by R.S.KHURMI AND J.K.GUPTA.
Automobile Engineering , KirpalSingh.
IV.
Automobile Engineering, S.M.Pandey& K.K. Shah.
www.wikipedia.com.
VI. Shigley Tata McGraw hills (Machine Design).
VII. Generation of Electricity through Speed Breaker
Mechanism. (Alok Kumar Singh, Deepak Singh, Madhawendra
Kumar , Vijay Pandit, Prof.SurendraAgrawal).
VIII. EVERY SPEED BREAKER IS NOW A SOURCE OF POWER.
(ASWATHAMAN.V ELECTRONICS AND COMMUNICATION
ENGINEERING SONA COLLEGE OF TECHNOLOGY SALEM, INDIA).

(PRIYADHARSHINI.M ELECTRONICS AND COMMUNICATION
ENGINEERING SONA COLLEGE OF TECHNOLOGY SALEM, INDIA).
46

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Generation of Electricity through Speed Breaker Mechanism

Generation of Electricity through Speed Breaker Mechanism

GENERATION OF ELECTRICITY THROUGH SPEED BREAKER

Department Of Mechanical Engineering

(A Constituent College of UET Lahore.)

Engr. Muhammad Qasim Tatla

Assistant Professor, Department of Mechanical Engineering

RACHNA COLLEGE OF ENGINEERING AND TECHNOLOGY, GUJRANWALA.

Generation of Electricity through Speed Breaker Mechanism

As partial fulfillment of the requirements for the

This report is submitted to

Department of Mechanical Engineering,

Rachna College of Engineering and Technology, Gujranwala

Internal Examiner: Engr. Muhammad Qasim Tatla

Department of Mechanical Engineering,

Rachna College of Engineering and Technology, Gujranwala

(A Constituent College of UET, Lahore)

Generation of Electricity through Speed Breaker Mechanism

I dedicate this work to my beloved parents for

Generation of Electricity through Speed Breaker Mechanism

Generation of Electricity through Speed Breaker Mechanism

INTRODUCTION OF THE PROJECT

2. SCOPE OF THE PROJECT

DEMONSTRATION OF THE PROJECT

CMODELLING, SIMULATION AND RESULTS8

2. FABRICATION MODEL SHOWING INNER PARTS

1. RACK AND PINION

5. OTHER ACCEPTABLE ARRANGEMENTS 15

6. LEAST RECOMMENDED ARRANGEMENTS

7. SPROCKET DIMENSIONAL SPECIFICATIONS 17

Generation of Electricity through Speed Breaker Mechanism

2. Chain Drive Design

WHEELS AND SPRINGS 28

DESIGN PARAMETER`S AND LIMITATION 38

1. OUTPUT POWER CALCULATIONS 39

3. SPROCKET WHEEL AND CHAIN

Generation of Electricity through Speed Breaker Mechanism

might conclude that to be materially rich and prosperous, a human

Generation of Electricity through Speed Breaker Mechanism

Generation of Electricity through Speed Breaker Mechanism

SCOPE OF THE PROJECT

Generation of Electricity through Speed Breaker Mechanism

Pakistan is facing serious energy crisis at this time .Pakistan as third

Generation of Electricity through Speed Breaker Mechanism

Generation of Electricity through Speed Breaker Mechanism

1 WORKING PRINCIPLE:The project is concerned with generation of electricity from speed

Here the reciprocating motion of the speed-breaker is converted into

Generation of Electricity through Speed Breaker Mechanism

RACK & PINION

Generation of Electricity through Speed Breaker Mechanism

Generation of Electricity through Speed Breaker Mechanism

2. FABRICATION MODEL SHOWING INNER

Generation of Electricity through Speed Breaker Mechanism

Sprocket wheelsMild steel

Speed breaker - Mild steel

SPECIFICATIONS:Generator - 12v DC generator

Generation of Electricity through Speed Breaker Mechanism

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.