Acknowledgment: Electricity Generation Form Speed Breaker

Electricity Generation form Speed Breaker ????-??
Acknowledgment
With due respect and gratitude we convey our sincere thanks to our worthy
lecturer guide Prof.R.D.Pawarkar for giving us this opportunity to undergo
this self-sponsored project. We also like to thank him for his all his support,
time and guidance towards this new project. We were privileged to work under
his guidance.
We are also thankful to our respected HOD, Prof. P.B.Joshi whose advices and
kind co-operation helped us to go through all difficulties and complete this
project.
Our special thanks to Prof.Borikar without whose inspirational guidance it was
not possible for us to bring this work at present stage.
I would also like to thanks all the staff members who helped us for their
valuable support towards this project.
Maharashtra Institute of Technology, Pune Page 1

LIST OF CONTENTS
SR.NO. NAME THE TOPICS PAGE

1. ABSTRACT 4
2. INTRODUCTION 5
3. PROBLEM STATEMENT 6
4. OBJECTIVES 9
5. SELECTION OF PROJECT 10
6. LITERATURE REVIEW 12
6.1. What is Electricity 12
6.2. Making Electricity 13

6.3. Electricity from Speed Breakers 17
6.4. Speed Breaker Specifications 22
6.5. Materials for Speed Breakers 23

6.6. Roller Mechanism 23
7.0 METHODOLOGY 26
7.1. Energy Transformation 26
7.2. Main Components 26
8.0 WORKING PRINCIPLE 32

9.0 MATERIAL SELECTION 34
9.1. Material Selection Factors 34
9.2. Material Properties 34
9.3. Materials Used 38

10.0 NOMENCLATURE 44
11.0 DESIGN 49
11.1. Design of transmission system 50
11.2. Torque induced on shaft 51
11.3. Design of Spur gear 52
11.4. Design of spring 55
11.5. Design of fillet welded joints 58
12.0 FABRICATION 60
13.0 BUDGET 61
14.0 TIME ACCOUNTING 62
14.1. Machine time estimation 62
14.2. Procedure for calculating machining time 62
14.3. Time analysis 63
14.4. Time Required for Machining time components 66
15.0 APPLICATIONS 68
16.0 ADVANTAGES AND DISADVANTAGES 69
17.0 FUTURE SCOPE 73
18.0 PRECAUTIONS & SAFETY MEASURES 77
18.1. Precautions 77
18.2. Safety Measures 77
19.0 REFERENCES 78
20.0 PHOTOS AND ASEEMBLY 80-81

1. ABSTRACT
Energy is the primary need for survival of all organisms in the universe.
Everything what happens in the surrounding is the expression of flow of energy
in one of the forms. Man in his lifetime, uses energy in one form or the other.
Electricity in our country is a big problem which is faced by people who reside
in the country. Due to day-to-day increase in population and reduction of the
conventional sources, it becomes necessary that we must depend on non-
conventional sources for power generation. The renewable sources of energy
become more popular because of nonpolluting.
The number of vehicles passing over the speed breaker on the road 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. So our aim of this project is to tap this energy and generate power by
making the speed-breaker as a power generation unit. The generated power can
be used for the lamps near the speed breakers, traffic signals and this will be a
great boon for rural areas too. The reciprocating motion of the speed-breaker is
converted into rotary motion using the rack and pinion is the basic principle
which we are going to use. Conversion of Kinetic to Electrical energy using
generator which will be saved with the use of a battery is our basic objective
and to generate maximum power output is our aim. The electrical output can be
improved by arranging these power humps in series. This generated power can
be amplified and stored by using different electric devices.

2. INTRODUCTION
Since last few decades, Power has become the most important need for human
life. But we know that the resources for power generation are limited, and this
has caused energy crisis. The increasing power demand results into reduce in
conventional resources for power generation and increase the carbon dioxide
emission; it provides a need to think on non-conventional energy resources or
renewable energy resources which are eco-friendly to environment. In this
project, it’s our objective to conserve the kinetic energy which is released from
friction of speed breakers every day. The Idea to generate electricity through
speed breakers can bring revitalization in field of power generation.
For reduction of carbon dioxide emission, renewable energies are considered as

proper alternative energy. Renewable energies mainly refer to the wind, solar,
biomass and marine currents which are less harmful to environment, attracting a
wide attention of researchers in design and development of renewable energy
conversion systems. Although improvement of renewable energy converters is
in a fast rate, the systems to extract the wasted energy in conventional energy
conversion systems are not developed as much as its technologies. In many
systems and processes, dissipation of energy is inevitable whatever renewable
or conventional energy was used. For instance, as a car passes over a speed-
breaker, most of car kinetic energy will be wasted as heat in it. On other hand,
to ensure the security of the populated areas of streets, the speed-breakers are
required. In this paper, we focus on the fixed speed-breaker at the streets since a
high amount of vehicles kinetic energy is wasting there. There are thousands of

crowed cities with enormous flow of vehicles offers high amount of energy can
be considered as near to urban resource of energy.
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 speed-breakers. 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. It’s 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. 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.
A survey has been conducted about electricity consumption from Tamil Nadu
electricity board website. It says that: The amount of electricity consumed in
one night by all the street lights around Chennai city is equal to consumption of
electricity in a remote village for one month and 14 day. This survey inspired us
a lot and made us to think about saving this wasted power which made us
introduce this new technique.


3. PROBLEM STATEMENT
To produce energy with the help of speed-breaker mechanism by using most

feasible mechanism to gain maximum output with minimum possible budget?

4. OBJECTIVES
∑ Low budget electricity generation.

∑ Less floor area utilisation.
∑ A large amount of energy is wasted when a vehicle passes over a speed-
breaker; objective of this project is to use this energy to produce
electricity at a minimum possible budget.
∑ This electricity produced can be used at parking of multiplexes,
shopping-malls, toll-booths, traffic signals, light-up the street lights, rural
welfare, etc.
∑ No obstruction to traffic.
∑ It is a renewable source of energy and can be used for man-kind.
∑ Conversion of Kinetic energy of vehicles into Electrical energy.
∑ Eco-friendly system.
∑ Using wasted kinetic and potential energy of vehicle at speed breaker.
∑ It is also a Green system.
∑ To produce a system which is not polluting.
∑ A system which does not leads to global warming.
∑ To produce electricity for self-sufficient power supply of toll-plazas.

5. SELECTION OF PROJECT
An engineer is always focused towards challenges of bringing ideas and

concepts to life. Therefore, sophisticated machines and modern techniques have
to be constantly developed and implemented for economical manufacturing of
products. At the same time, we should take care that there has been no
compromise made with quality and accuracy.
In the age of automation machine become an integral part of human being. By

the use of automation machine it is proved that it gives high production rate
than manual production rate. In competition market everyone wants to increase
their production & make there machine multipurpose.
The engineer is constantly conformed to the challenges of bringing ideas and
design into reality. New machines and techniques are being developed
continuously to manufacture various products at cheaper rates and high quality.
Growing economies, especially of Asia are gifted with sufficient resource base
and non-conventional energy technologies are consistent both for grid linked
energy generation and transmission in out of that are islanded from the
grid. Adaptation of technology and employing them should be pursued right
from this moment to have a head start, be informed of the barriers in technology
applications of the renewable variety and synergizing them with the existing,
traditional power production technology and T&D networks. It is known that in
coming times, wind energy will be the most cost-effective renewable resource.
Yet, it is doubtful if any individual technology would hold center-stage.

Thus we selected kinetic generator means the “Energy in motion when it is

suddenly applied with a sort of obstacle, then according to Newton’s law for
every action there is an equal and opposite reaction. Utilization of this reaction
is the basic reason behind the selection of this project work.”
AVAILABLE FLEXIBLE POWER

ENERGY OF SPEED GENERTAED IN
THE MOVING BREAKER TERMA OF
VEHICLE TO TRAIN OF GLOWING
APPLY GEAR AND BULB OR
IMPACT PULLEYS AND CHARGING
FORCE ON GENERATOR BATTERY
THE SPEED SYSTEM
BREAKER
FIG 1: the set up flow diagram

6. LITERATURE REVIEW
6.1 WHAT IS ELECTRICITY?
Electricity is a form of energy. Electricity is the flow of electrons. All matter is

made up of atoms, and an atom has a center, called a nucleus. The nucleus
contains positively charged particles called protons and uncharged particles
called neutrons. The nucleus of an atom is surrounded by negatively charged
particles called electrons. The negative charge of an electron is equal to the
positive charge of a proton, and the number of electrons in an atom is usually
equal to the number of protons. When the balancing force between protons and
electrons is upset by an outside force, an atom may gain or lose an electron.
When electrons are "lost" from an atom, the free movement of these electrons
constitutes an electric current.
Electricity is a basic part of nature and it is one of our most widely used forms
of energy. We get electricity, which is a secondary energy source, from the
conversion of other sources of energy, like coal, natural gas, oil, nuclear power
and other natural sources, which are called primary sources. Many cities and
towns were built alongside waterfalls (a primary source of mechanical energy)
that turned water wheels to perform work. 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. Beginning with Benjamin Franklin's experiment with a kite one stormy
night in Philadelphia, the principles of electricity gradually became understood.
In the mid-1800s, Thomas Edison changed everyone's life -- he perfected his
invention -- the electric light bulb. Prior to 1879, electricity had been used in arc

lights for outdoor lighting. Edison's invention used electricity to bring indoor
lighting to our homes.
6.2. MAKING ELECTRICITY
Electricity can be made or generated by moving a wire (conductor) through a

magnetic field.
Magnetism
Diagram 1
A bar magnet has a north and south pole. If it is placed under a sheet of paper
and iron filings are sprinkled over the top of the paper, these iron filings will
arrange themselves into a pattern of lines that link the north pole with the south
pole of the magnet (see diagram 1). These lines show the magnetic field around
the magnet.

Diagram 2
If a coil of wire is moved within a magnetic field so that it passes through the
magnetic field, electrons in the wire are made to move (as in diagram 2). When
the coil of wire is connected into an electric circuit (at the terminals ‘A’ and ‘a’)
the electrons are under pressure to move in a certain direction and a current will
flow. This electrical pressure is called voltage. The amount of pressure or
voltage depends on the strength and position of the magnetic field relative to the
coil, as well as the speed at which the coil is turning. As the amount of
electricity changes so does its voltage.
Diagram 3

Diagram 4
Diagram 5
Diagram 6

In the diagram above, the coil of wire is rotating in a clockwise direction. When
the coil of wire is in the horizontal position 1the voltage is greatest (diagram 3)
because the coil is passing through the strongest part of the magnetic field. At
this stage the current flows from 1 to 2 to 3 to 4, out through terminal ‘A’,
through the globe and back into terminal a. When the coil of wire is in the
vertical position (2), no electricity is produced because the coil does not cut the
magnetic field, and no current flows. When the coil of wire is in the horizontal
position again 3 the voltage is at its maximum (3), however the current flows in
the opposite direction 4 to 3 to 2 to 1, out through terminal ‘a’, through the
globe, and back into terminal ‘A’. The current produced changes direction every
half turn (180 degrees). This is called alternating current or AC. The generators
at large power stations produce nearly all the electricity we use in this way. The
energy crisis is a bottleneck in the supply of energy resources to an economy.
The studies to sort out the energy crisis led to the idea of generating power
using speed breaker. First to make use were South African peoples, their
electrical crisis has made them to implement this method to light up small
villages of the highway. The idea of basic physics to convert the kinetic energy
into electrical energy that goes waste when the vehicle runs over the speed-
break was used. Since then a lot has been done in this field. The idea caught our
working team and we have decided to develop such a project that will produce
more power and store it for use at night time as it proves to be a boon to the
economy of the country.
Long ago when the first modes of transport were invented, the roads were very
uneven. Then by experience people realized that smoother roads could help in
faster travelling speeds. But then again too smooth a surface would not let the

wheel move ahead and would rather make it slip in its position. Maybe then a
basic understanding of how friction works came into their minds and they made
the roads rough and added speed breakers and Ramblers so that speed could be
controlled and over speeding - avoided.
6.3. ELECTRICITY FROM A SPEED BREAKER
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.
The Burger King in U.S. 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 will both
help them slow down and harvest some of that coasting energy.

Speed Bump
In the future, New Energy may employ flywheels, super-capacitors or some other form
of storage, but this demonstration is intended just to prove that the speed bump won't
fold under continuous pressure from the 1,000 pounds per wheel of weight from an
average car. The weight of a car is used to throw a lever, explains Gerard Lynch, the
engineer behind the Motion Power 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
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 and hopes to develop the next
generation of the technology, which could be employed anywhere from the
local fast food joint to rumble strips at toll plazas 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.


When pressure lever is pressed the flywheel will rotate by chine sprocket gear
mechanism, it will force to rotate the DC generator because DC generator and
flywheel are in same shaft. DC generator will produce electricity by the rotation
of armature coil and generated electricity will be stored in a rechargeable
battery. This electricity can be used later for lighting bulb during night time on
the road side.

6.4. SPEED BREAKER SPECIFICATIONS

Design specifications are based on the RK-10, RK-18 and RK-36 preformed
speed breakers as manufactured by Road Kare International and distributed by
Lake Traffic Solutions, phone 925-930-9603.

In order to consistently meet the following specifications, the speed breakers

shall be manufactured in the USA by an ISO 9002 approved company. Other
manufacturers may be approved with prior approval from architect/engineer.
6.5. DIMENSIONS
The speed breaker shall be modular in design with the standard length being 6′.
Additional sections can be added in 2′ increments to desired length. Fixed size
speed breaker substitutes shall not be accepted.
RK-10 is designed to reduce vehicle speed to less than 10 mph. Each module of
the RK-10 is 10″ W x 2′ L x 2 1/8″ H. Centre module has one reflective yellow
“X” moulded-in marking. End module is tapered at the end with one reflective
yellow moulded-in “X” marking.
the RK-18 is 18″ W x 2′ L x 2 1/4″ H. Centre module has two unique shaped 8″
reflective moulded-in yellow chevrons facing opposite directions. End module
is tapered at the end with one reflective moulded-in yellow diamond to indicate
the end of the speed breaker.
the RK-36 is 36″ W x 2′ L x 2 1/2″ H. Centre module has two unique shaped
12″ reflective moulded-in yellow chevrons facing opposite directions. End
module is tapered at the end with one reflective moulded-in yellow diamond to
indicate the end of the speed breaker.
6.6 MATERIAL
Speed breaker modules shall be made from 100% recycled rubber and a two-
part polyurethane binder making the speed breaker impervious to motor fuels,
oils, solvents, road salts and outdoor environment. The rubber shall be obtained
from recycled truck and tractor tire treads only (which is all rubber as compared

to car tires which contain synthetic rubber). The rubber, in fibre form up to 1/2″
long, shall contain no rubber dust, granules or fly that will weaken the final
product. They shall be compression moulded and have the following properties:
• Shore A Hardness: 65 minimum
• Specific Gravity: 1.13
• Skid Resistance: 89 (dry)
• Tensile Strength: 500 p.s.i. minimum
• Deform Rate: None (100% recovery after compression)
All shall be black in colour with all markings made of pavement marking tape
and moulded into the rubber for long term durability. Markings that are painted
on or applied with adhesives shall not be acceptable. WARRANTY RK-10,
RK-18 and RK-36 preformed speed breakers and markings are guaranteed for 2
years under normal use when installed according to manufacturer’s
specifications.
6.7 ROLLER MECHANISM

This project explains the mechanism of electricity generation from speed

breakers. The friction force due to vehicle movement acted upon the speed
breaker system is transmitted to chain sprocket arrangements. The sprocket
arrangement is made of two sprockets. One of the sprocket is larger in
dimension than the other sprocket. Both the sprockets are connected with chain
which transmits the 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
gear arrangement. Here we have two gears with different dimensions. The gear
wheel with the larger diameter is coupled to the axis of the smaller sprocket.
Hence, the speed that has been increased at the smaller sprocket wheel is passed
on to this gear wheel of larger diameter.

7. METHODOLOGY
7.1. ENERGY TRANSFORMATION

Here following method is adopted to generate the electricity:-
∑ The set up is designed.
∑ It’s subcomponents are manufactured
∑ The sub components are assembled together
∑ The set up is tested for checking whether it performing it’s intended task
or not.
Under this method the fly wheel is the key component for energy
transformation.
Speed Braker
arrangement Generator
Battery
Rack and
Pinion
Flywheel Inverter
arrngemen
t
Sprocket Street
Gear Drives
arrangement Lights

7.1. MAIN COMPONENTS

i. Rack
ii. Spur gear
iii. Fly wheel
iv. Bearings
v. Shaft
vi. Springs
vii. Electric dynamo OR Generator
7.1.1. Rack:
It is long rectangular round having teeth on one end. It is used to transmit the
translational motion into rotational motion.
7.1.2. 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.
7.1.3. Flywheel:
Flywheel is a device to smoothen the cyclic fluctuation of speed change when

delivering constant output power from the engine. It has no influence on the
mere speed of the prime mover. It has no influence on the varying load demand

on the prime mover or the delivered power from the prime mover. In is the
forgoing discussion, it is observed that turning moment diagrams for the cycle
show period during which torque is in excess of the mean torque responsible for
the constant power output and also periods during which the torque is less than
the mean torque. Thus the speed of the flywheel would increase during period
of excess of torque during the cycle and the speed will fall during the period of
the deficit torque during the cycle. Thus a flywheel stores energy and releases
energy during the cycle without affecting mean energy output. Thus a properly
designed flywheel has to ensure the cyclic fluctuations of speed within
prescribed limits preferably as small as possible.
7.1.3.1. Definition of the flywheel
A flywheel used in machine serves as a reservoir which stores energy during

the period when the supply of energy is more than the requirement and releases
it during the period when the requirement of energy is more than the supply.
7.1.3.2. Working of the flywheel
The excess energy is developed during power stroke is absorbed by flywheel

and releases it to the crankshaft during the other stroke in which no energy is
developed, thus rotating the crankshaft at a uniform speed. A little
consideration will show that when the flywheel absorbs energy, its speed
increases and when it releases energy, the speed decreases. Hence a flywheel
does not maintain a constant speed, it simply reduces the fluctuation of speed.
In other words, a flywheel controls the speed variations caused by the
fluctuation of the engine turning moment during each cycle of operation.

7.1.3.3. Application
Flywheel are mostly used in machine where the operation is intermitted like
punching machines, shearing machines, riveting machines, crushers etc, the
flywheel stores energy from the power source during the greater portion of the
operating cycle and gives it up during a small period of the cycle. Thus the
energy from power source to the machines is supplied practically at a constant
rate throughout the operation.
7.1.4. Shaft
A shaft is a rotating element, which is used to transmit power from one place to
another.
7.1.5. 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.
7.1.6. 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.
These are mainly:
1. Helical springs
2. Torsion springs
3. Involute spring
4. Conical casting laminated or leaf spring.We are using Helical compression
springs.
7.1.7. Dynamos
A dynamo is an electrical generator that produces direct current with the use
of a commutator. Dynamos were the first electrical generators capable of

delivering power for industry, and the foundation upon which many other later
electric-power conversion devices were based, including the electric motor, the
alternating-current alternator, and the rotary converter. Today, the simpler
alternator dominates large scale power generation, for efficiency, reliability and
cost reasons. A dynamo has the disadvantages of a mechanical commutator.
Also, converting alternating to direct current using power rectification devices
(vacuum tube or more recently solid state) is effective and usually economical.


8. WORKING PRINCIPLE
The project is concerned with generation of electricity from speed breakers-like

setup. 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. Rack and
pinion mechanism is the most efficient mechanism out of all mechanism. It
gives higher transmission ratio and power output than other mechanism.
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. Both the sprocket are connected to the pinion gears with the help of
nylon shaft. It is been bored and fixed with each other. Further it is connected to
other set of gear driven which is separated by an acrylic frame. The sprocket
transmits the motion with the help of M.S. steel shaft which is the connecter
between these two sets. Further it transmits motion and power to the second set
of gear drives which drives the flywheel.
The USP of this system is that as one of the pinion rotate in one direction i.e.
rack travel down when the load is applied; the sprocket too rotates and transmits
power and motion, while the other sprocket will only rotate and not transmit
power and motion. Now when it completes one complete cycle, the pinion gears
has to travel up due to tension springs used in the mechanism. As it travels up,
the other gear drives the sprocket which will now transmit power and motion
which the other sprocket only rotates without transmitting power and motion.
Hence power output is obtained while the speed breaker goes up and down and

gives more efficiency than other system. This is the advantage of using
unidirectional sprocket.
Hence, though the speed due to the rotary motion achieved at the smaller
sprocket wheel is more, 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.

9. MATERIAL SELECTION
9.1. MATERIAL SELECTION FACTORS
The proper selection of material for the different part of a machine is the main
objective in the fabrication of machine. For a design engineer it is must that he
be familiar with the effect, which the manufacturing process and heat treatment
have on the properties of materials. The Choice of material for engineering
purposes depends upon the following factors:
1. Availability of the materials.
2. Suitability of materials for the working condition in service.
3. The cost of materials.
4. Physical and chemical properties of material.
5. Mechanical properties of material.
9.2. MATERIAL PROPERTIES
The mechanical properties of the metals are those, which are associated with the
ability of the material to resist mechanical forces and load. We shall now
discuss these properties as follows:
1. Strength : It is the ability of a material to resist the externally applied
Forces
2. Stress: Without breaking or yielding. The internal resistance offered by a
part to an externally applied force is called stress.
3. Stiffness: It is the ability of material to resist deformation under stresses.
The modules of elasticity of the measure of stiffness.
4. Elasticity: It is the property of a material to regain its original shape after
deformation when the external forces are removed. This property is
desirable for material used in tools and machines. It may be noted that
steel is more elastic than rubber.

5. Plasticity: It is the property of a material, which retain the deformation

produced under load permanently. This property of material is necessary
for forging, in stamping images on coins and in ornamental work.
6. Ductility: It is the property of a material enabling it to be drawn into wire
with the application of a tensile force. A ductile material must be both
strong and plastic. The ductility is usually measured by the terms,
percentage elongation and percent reduction in area. The ductile materials
commonly used in engineering practice are mild steel, copper, aluminum,
nickel, zinc, tin and lead.
7. Brittleness: It is the property of material opposite to ductile. It is the
Property of breaking of a material with little permanent distortion. Brittle
materials when subjected to tensile loads snap off without giving any
sensible elongation. Cast iron is a brittle material.
8. Malleability: It is a special case of ductility, which permits material to be
rolled or hammered into thin sheets, a malleable material should be
plastic but it is not essential to be so strong. The malleable materials
commonly used in engineering practice are lead, soft steel, wrought iron,
copper and aluminum.
9. Toughness: It is the property of a material to resist the fracture due to
high impact loads like hammer blows. The toughness of the material
decreases when it is heated. It is measured by the amount of absorbed
after being stressed up to the point of fracture. This property is desirable
in parts subjected to shock an impact loads.
10.Resilience: It is the property of a material to absorb energy and to resist
rock and impact loads. It is measured by amount of energy absorbed per

unit volume within elastic limit. This property is essential for spring
material.
11.Creep: When a part is subjected to a constant stress at high temperature

for long period of time, it will undergo a slow and permanent deformation
called creep. This property is considered in designing internal combustion
engines, boilers and turbines.
12.Hardness: It is a very important property of the metals and has a wide
variety of meanings. It embraces many different properties such as resistance
to wear scratching, deformation and Mach inability etc. It also means the
ability of the metal to cut another metal. The hardness is usually expressed in
numbers, which are dependent on the method of making the test. The
hardness of a metal may be determined by the following test.
a) Brinell hardness test
b) Rockwell hardness test
c) Vickers hardness (also called diamond pyramid) test and
d) Share scaleroscope.
The science of the metal is a specialized and although it overflows in to realms
of knowledge it tends to shut away from the general reader. The knowledge of
materials and their properties is of great significance for a design engineer. The
machine elements should be made of such a material which has properties
suitable for the conditions of operations. In addition to this a design engineer
must be familiar with the manufacturing processes and the heat treatments have
on the properties of the materials. In designing the various part of the machine it
is necessary to know how the material will function in service. For this certain
characteristics or mechanical properties mostly used in mechanical engineering
practice are commonly determined from standard tensile tests. In engineering

practice, the machine parts are subjected to various forces, which may be due to
either one or more of the following.
1. Energy transmitted
2. Weight of machine
3. Frictional resistance
4. Inertia of reciprocating parts
5. Change of temperature
6. Lack of balance of moving parts
The selection of the materials depends upon the various types of stresses that
are set up during operation. The material selected should with stand it. Another
criteria for selection of metal depend upon the type of load because a machine
part resist load more easily than a live load and live load more easily than a
shock load.
Selection of the material depends upon factor of safety, which in turn depends
upon the following factors.
1. Reliabilities of properties.
2. Reliability of applied load.
3. The certainty as to exact mode of failure.
4. The extent of simplifying assumptions.
5. The extent of localized.
6. The extent of initial stresses set up during manufacturing.
7. The extent loss of life if failure occurs.
8. The extent of loss of property if failure occurs.

9.3. MATERIAL USED
1.MILD STEEL
Reasons:
1. Mild steel is readily available in market.
2. It is economical to use.
3. It is available in standard sizes.
4. It has good mechanical properties i.e. it is easily machinable.
5. It has moderate factor of safety, because factor of safety results in
unnecessary wastage of material and heavy selection. Low factor of
safety results in unnecessary risk of failure.
6. It has high tensile strength.
7. Low co-efficient of thermal expansion.
Properties of mild steel:

M.S. has carbon content from 0.15% to 0.30%. They are easily wieldable thus
can be hardened only. They are similar to wrought iron in properties. Both
ultimate tensile and compressive strength of these steel increases with
increasing carbon content. They can be easily gas welded or electric or arc
welded. With increase in the carbon percentage weld ability decreases. Mild
steel serve the purpose and was hence was selected because of the above
purpose.
2. MS C45-
It has Carbon percentage ranging from 0.40-0.50 and about 0.60-0.90
percentage of Manganese.it is mainly used for spindles of machine tools, bigger

gears, bolts and shafts. Ultimate tensile stress and bending stress is about 160
2
N/mm .
3. NYLON GEAR-
Molded plastic gears have long provided alternatives to metal gears in lightly
loaded drives. They transmit power quietly and often without lubrication in
applications such as food processors, windshield wiper drives, and even
watches. They also reduce the number of parts and resist chemicals in many
applications.
Previously, plastic gears were limited to ¼-hp drives because of variations in

their properties and uncertainties about how they respond to environmental
conditions such as moisture, temperature, and chemicals.
Today, better molding controls combined with design practices that more
accurately encompass environmental factors have boosted plastic gear drive
capacity to ¾-hp.
Though plastic gears give engineers more flexibility, designing them is more
complicated. Their material properties and dimensions vary with changes in
environmental conditions, thereby affecting speed reducer capabilities.
Few, if any, engineers have sufficiently broad expertise to design speed

reducers with plastic gears. Therefore, the first step is to assemble a team of
experts consisting of at least a gear engineer, plastics engineer, and plastics
supplier. Other valuable additions may include a manufacturing engineer,
quality control engineer, molder, and tool builder.

The team's objective is to design each gear set for nominal operating conditions,
fine-tune the design for worst-case operation, and create detailed specifications
for producing prototype and production gears.
Plastics aren't metals
Before starting the design process, engineers accustomed to designing metal

gears need to understand the major properties of plastics that affect gear
performance. These include strength, elastic modulus, thermal expansion,
moisture absorption, and friction characteristics.
Plastics have much lower strengths than metals. For example, bending strength
ranges from 12,000 to 45,000 psi, depending on the specific material. This
means larger gears to carry the same load. However innovative designs, such as
those that split the torque between two or more gears operating in parallel, can
minimize the size of a gear set.
Plastic materials for gears
Crystalline type plastics generally provide characteristics that ensure reliable

gear operation, as well as consistent shrinkage needed for precision molding.
These materials include nylon 6/6, polydactyl, polyphenylene sulfide (PPS),
thermoplastic polyester, long fiber reinforced plastic and liquid crystal polymers
(LCP).
Most plastic gears are made from nylon and acetyl. But nylon absorbs moisture
with resultant changes in properties and dimensions. Acetyl copolymers provide
long-term dimensional stability as well as high fatigue and chemical resistance
over a wide temperature range.

Thermoplastic polyesters are also more dimensionally stable than nylon. Where
no lubricant is used, both nylon and polyester provide good lubricity when
mated with polydactyl.
Liquid crystal polymers give high dimensional stability and chemical resistance,
plus low mold shrinkage and high accuracy. To date they have been used only
for small gears under light loads, such as watch gears.
Linear polyphenylene sulfides have high temperature and chemical resistance

and good fatigue life. They work well in highly loaded parts molded with fine
details.
Long fiber reinforced plastics provide good dimensional repeatability and

shrinkage consistency in large parts. Moreover their high stiffness, plus creep
and impact resistance make them suitable for gear housings.
Non-crystalline plastics have found limited success for gear applications. ABS
is suitable only for lightly loaded gears. Polycarbonate usually requires glass
reinforcement or a solid lubricant such as PTFE to obtain satisfactory lubricity,
chemical resistance, and fatigue properties.
Why plastic?
For drive designers, plastic gears offer several benefits including design
flexibility, reduced noise, and the ability to operate without lubrication. Other
benefits include lower cost and weight, higher efficiency, (improved accuracy),
and chemical resistance.
Design flexibility

The design opportunities that plastic gears afford are a major advantage. They
can be molded in shapes difficult to machine in metal. Other functional
elements such as springs and pawls can be molded into them, thereby
consolidating parts and trimming the cost, weight, and complexity of geared
speed reducers.
Cost
They are molded in high volumes at low cost, typically one-half to one-tenth
that of stamped, machined, or powder metal gears. They're usually ready to use
as-molded and require no finishing.
Weight: Plastics inherently weigh less, typically 15 to 20% as much as steel, but
plastic gears must be larger to transmit the same power.
Noise
Compared with metal, plastic gears run much quieter. Depending on the
application, their sound level compares to that of metal gears one or two AGMA
numbers higher in quality. Plastic gear teeth deform, compensating for noise-
producing gear misalignment and tooth errors, and the material absorbs impacts
that would otherwise cause running noise.
Efficiency
A low coefficient of friction means less horsepower wasted in heat. Plastic

gears also lend themselves to efficient designs such as split-path planetary
drives.
Lubrication
Inherent lubricity and chemical resistance mean plastic gears can be used with
or without lubrication as needed for specific applications.
Accuracy

With consistent material quality, and accurate molding process control, plastic
gears can achieve high precision -- up to AGMA Quality 10.
Durability
Chemical and corrosion resistance typically exceeds that of metal gears,

especially in wet applications.

10. Nomenclature
10.1. GENERAL TERMINOLOGIES OF GEARS
1. 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.
2. Gear, wheel
The larger of two interacting gears or a gear on its own.
3. Pinion
The smaller of two interacting gears.
4. Path of contact
Path followed by the point of contact between two meshing gear teeth.
5. 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.
Forinvolute 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.
6. Axis
Axis of revolution of the gear; center line of the shaft.

7. Pitch point, p
Point where the line of action crosses a line joining the two gear axes.
8. 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.
9. 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.
10. 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.
11. Operating pitch diameters
Diameters determined from the number of teeth and the center distance at which
gears operate.
12. 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.

13. 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.
14. Arc of action
Segment of a pitch circle subtended by the angle of action.
15. 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,
16. Outside diameter,
Diameter of the gear, measured from the tops of the teeth.
17. Root diameter
Diameter of the gear, measured at the base of the tooth.
18. Addendum, a
Radial distance from the pitch surface to the outermost point of the tooth
.
19. Dedendum, b
Radial distance from the depth of the tooth trough to the pitch surface.
20. 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.
21. Clearance
Distance between the root circle of a gear and the addendum circle of its mate.

22. Working depth

Depth of engagement of two gears, that is, the sum of their operating
addendums.
23. 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.
24. Diametral pitch,
Ratio of the number of teeth to the pitch diameter.Could be measured in teeth
per inch or teeth per centimeter.
25. 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.
26. 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.
27. Interference
Contact between teeth other than at the intended parts of their surfaces.
28. Interchangeable set
A set of gears, any of which will mate properly with any other.
29. G=Gear ratio
30. Tp=Number of teeth on Pinion
31. Tg=Number of teeth on Gear
32. Wn=Load on tooth
33. Wc= Load on bearing of wheel
34. Sut=Ultimate tensile stress

35. Syt=Yield strength
36.
Where,
M = Moment couple
I = Mass moment of Inertia
σb = Bearing stress
37. BMmax = Maximum bending moment
38. K = Wahl factor
K=

11. DESIGN
11.1. DESIGN OF TRANSMISSION OF SYSTEM
As in our project input is weight of moving vehicle is transmitted towards rack,

rack transmits the linear movement to rotary with the help of pinion meshed
with it. As the rack goes down the pinion completes its one revolution. With the
help of digital tachometer we find that pinion rotates with 60 rpm.
PINION
RACK
1 REVOLUTION
The pinion has 65 teeth on it, the same rotation is transmitted to the similar spur
gear mounted on same shaft, and unidirectional free it is between both spur
gears, meshed with bigger spur gear with 75 no of teeth on it.
the rotation of bigger spur gear is calculated as
Big gear rotation N small gear

=
Small gear rotation N big gear

Big gear rotation 65

=
60 75
Big gear rotation = 65 × 60

75
Big gear rotation = 55.7 rpm
Now, this same 55.7 rpm is transmitted to dynamo with the help of gear train of
same teeth. So we have selected a standard dynamo of 300 rpm to generate
electricity.
The flywheel is storing kinetic energy of rotation. Under full load condition the
flywheel rotate at a speed of 55.7 rpm & this rpm is given to dynamo.
Therefore, Speed of flywheel will be 55.7 Rpm if we are not using free wheel
here, but because of free wheel and fly wheels weight, actual RPM will
increase.
So, we find RPM of Flywheel is 55 RPM.
Diameter of flywheel = 200mm.
Mass of flywheel = 0.781 kg.
We know that the mean kinetic energy of the flywheel
? ? ?
E= (in N-m or joules)
?
Where,
m = Mass of the flywheel in kg,
k = Radius of gyration of the flywheel in meters, The radius of gyration (k) may
be taken equal to the mean radius of the rim (R)
I = Mass moment of inertia of the flywheel about its axis of rotation in kg-m2 =
m.k2

1 × 0.78 × 0.05? × 2? × 55
=
2 × 60
= 0.005616 N-m
So, we will buy 100 Rpm standard dynamo from the market, which will
produce 10 watts power at his full speed.
11.2. CALCULATION OF TORQUE INDUSED ON SHAFT
In our project load is applied by bike is 100 kg. = 1000 N, but this load is
divided since it is mounted on two supports so actual load will be 500 N
This 500N is transferred to pinion gear through rack.
Diameter of pinion gear is 60mm. So Torque generated
T = F × D/2
T =500 × 60/2
T = 15000 N-mm
For applied torque we first design diameter of pinion shaft

Material C45 – 0.45 % carbon
σut = 320 N/mm2
Take FOS = 4
Now,
σt = σb = σultimate / FOS = 320/2 = 160 N/mm2.
σs = σt / 2 = 160/2 = 80 N/mm2.
The pinion shaft is subjected to pure twisting moment σs

We know,
16 × ?
?? =
? × ??
16 × 15000
?? =
3.14 × 80
d = 10.2 mm
But we are using 15mm shaft so our design is safe
11.3. DESIGN OF SPUR GEAR
We will cheek weather our gear teeth is safe for the desired load or not.
Our first gear is subjected to high load torque on flapper shaft.
So By Lewis equation we can find the maximum load gear can bear
Lewis equation
WT = σ.w.b.pc.y
The permissible working stress (σw) in Lewis equation depend upon the material
& may be obtained by both formula
σw = σo x Cv
σo = allowable static stress at elastic limit of the material
4.5
?? =
4.5 + ?
???
?=
60
? × 0.06 × 250
?=
60
v = 0.78 m/s

4.5
?? =
4.5 + 0.8
Cv = 0.85
Y is know as Lewis form factor or tooth from factor
0.912
? = 0.154 −
?
For 20 full depths involutes system
0.912
? = 0.154 −
20
Y = 0.1
Put the values in Lewis equation
WT= σo × Cv × b × pc ×Y
= 180× 106 × 0.85 × 0.01 × 2.9 × 10-3 × 0.124
= 550.2 N
= 56.1 Kg
Now torque will remain same throughout gear but force will change according
to diameter
T=f×R
= 15000 = f × 30
F = 500 N = 51 kg
Therefore max load on gear teeth will be 51 kg

550.2 N > 500N
Therefore our design is safe.

Module, m this indicates the tooth size and is the number of mm of pitch circle
diameter (p.c.d.) per tooth. For gears to mesh, their modules must be
equal. Gear ISO standards and design methods are now normally based on
the module. EG a gear of module 2.54 has 24 teeth, its pitch circle diameter is:
2.54 x 24 = 60.96 mm.
Selecting the module of pinion gear
?
Module = m =
?
??
m= = 0.92 mm = 1 mm
??
for pinion of 60 mm dia and 65 no of teeth.
?? ?.??? ? ??
Circular pitch = Pc = = = 2.9 mm
? ??

Dp × m =1
Dp = 1.08
The addendum is the height by which a tooth of a gear projects beyond

(outside for external, or inside for internal) the standard pitch
circle or pitch line; also, the radial distance between the pitch diameter
and the outside diameter.
Addendum = A = 1/Pd =0.92mm
Pitch diameter Pd = T / Dp = 65 / 1.08 = 60.2
Thickness of tooth = t = Pd × sin90/N = 0.92 mm
Whole depth = 2.157 × m = 1.98
Dedendum ( B ) = whole depth – addendum = 1.06
OD =T+2÷Pd
Root dia = (R D ) = T-2÷Pd
Base circle = BC = D × cos ( Pd × A )
Circular pitch (CP) = 3.1416D ÷ N = 2.89 mm
Circular thickness (T ) = 3.1414D ÷ 2N = 1.44 mm
Working depth = 2 × m = 1.84 mm
Whole depth = 2.157 × m = 1.98
Clearance = 0.2 ÷ Dp =0.185 mm
11.4. DESIGN OF SPRING
The spring is used to return back rack in upward direction. From trial and error
method we select spring with outer dia 24 mm and inner dia 18 mm due to size
restriction. (take shear modules, G= 80000 N/mm2 )

Di = 18 mm
For average service life of 422 N/mm².
Wire diameter range is 2 to 4 mm
We get wire diameter d = 2 mm from range
Outer diameter of spring = Di + (2 x 3)
Do = 24 mm.
Calculating the load bearing capacity of spring
Spring index = C = D/d =24/3= 8
C=8
Wahl factor
4?−1 0.615
K=
4?−4 ?
For C =8, K= 1.18
Now to find ‘P’,
We know
8KPDo
shear stress =
πd?
480× 3.14× 33
?
8× 1.18× 24
P = 157.9 N
P = 16.09 kg
Applied load is limited to 16.09 kg so we select two springs with combine load
bearing capacity of 32.18 kg.
So the design of spring is safe.
Spring rate = P/δ = 157.9 / 30 = 5.26 N /mm

K = 1.18 N/mm.
Calculation of number of turn of spring

We know
8 × ? × ??? × ?
?=
???
8 × 157.9 × 24? × ?
30 =
80000 × 3?
N = 13 Turns
Solid length of spring Ls = (N+2)×d
= 15 × 3
= 45 mm.
SUMMARY OF SPRING
Wire dia d = 3 mm
Coil dia Do = 24mm
Inner dia Di = 18 mm
Solid length = Ls =45 mm
No of active turns = 13
Spring rate K = 1.18 N/mm
Deflection = 30 mm

Let the total weight (P) of our project and bike be 200 kg, now this 200 kg
weight is kept on four angle,
P = 200/4 = 50 kg.
P = 50 × 9.8 = 490 N.
B=3 0mm b= 26 mm
L = 300 mm.
M = WL/4 = 490 × 160/4
= 19600 N-mm
4mm
?? ??
?= −
6 6? 30 mm
30? 26?
?= −
6 6 × 30
Z = 1961 mmᶟ
= M/Z = 19600/1961 = 10 N/mm²
As induced bending stress is less then allowable bending stress i.e. 160 N/mm2
design is safe.
11.5. DESIGN OF FILLET WELDED JOINT

Checking the strength of the welded joints for safety,

The transverse fillet weld is used in our project for making the frame for bike.
The maximum load which the plate can carry for transverse fillet weld is-
P = 0.707 × S × L × fs
Where, S = size of weld (welding rod dia) = 3.5 mm,

L = welding length = 20 mm
As load of bike is divided on whole frame, Take load of 500 N for any welded
joint Hence,
500 = 0.707 × 3.15 × 20 × fs
Hence let us find the safe value of ‘fs’
Therefore fs = 175/( 0.707 × 3.5 × 30)
fs = 10.10 N/mm2
Since the calculated value of the tensile load is very smaller than
The permissible value as fs=21 N/mm2.
Hence welded joint is safe.

12. FRABRICATION
Component Material/Specification Operations
Rack M.S Standard
Shaft M.S Power hacksaw ,
Hardening
Gears Teflon Standard, boring for
shaft fitting
Nylon shaft Nylon Cutting, facing,
turning
Sprocket Harden steel Standard
Ring (wheel) Polymer Cutting, boring
Spring Spring steel Spring coil m/c,
hardening
Frame MS C45 Standard angular,
welding, cutting
Pipe PVC Cut
DC motor 12 V, 150rpm Standard
Light system LED
Separating plates Acrylic sheet Cutting
Plywood frame Plywood Cutting
Stand for gearbox Iron Cutting, welding
Flywheel M.S. Welding

13. BUDGET
Material Cost/Item Quantity Total Cost
(INR) (INR)
Rack 120 1 120
Gears 133 6 798
Sprocket 55 3 165
Spring 90 2 180
Shaft I]120 2 240
II] 60 4 240
Bearing 50 3 150
Plywood frame 485 1 485
Iron frame 550 1 550
Pipe 330 1 330
Polymer rings 60 2 120
Flywheel 300 1 300
LED 20 1 20
Acrylic sheet 450 1 450
Nuts, Screws and 160 160
Bolts
Motor [150rpm] 230 1 230
Ramp spring 75 2 150
supporter
TOTAL 4688

14. TIME ACCOUNTING
14.1. MACHINING TIME ESTIMATION:-

The machining cost estimation gives us time require to machine a particular
component on machine. This gives us an estimation of how much time will be
required to hire the machine for that particular component.
This is done for all components except standard parts.
14.2. PROCEDURE FOR CALCULATING MACHINING TIME:-
1) After the machining time has been calculated including allowance for each
component because a component can have more than one operation to be
carried out. Hence, rates of machine are different.
2) The machining time is calculated using standard working rates.
3) The time required to manufacture a given component on a machine is
multiplied by machine rate to give machine cost.
4) The estimation of machining cost for total number of components gives us
machining cost estimation.
5) Machining time of components are estimated in order to know total
manufacturing cost of component.

Total time includes basic time & various other factors which are taken into
consideration & they are : -
1) Up time & down time = 10% of basic time.
i. Transportation time = 10 minutes.
ii. Centime time = 20 minutes
iii. Inspection time = 20 minutes
Other allowances taken into consideration are:
1) Personal allowance = 5% of basic time
2) Fatigue allowance = 7% of basic time
3) Contingency allowance = 5% of basic time
14.3. TIME ANALYSIS
∑ Turning Operation :
The machining time in a lather work can be calculated for particular
operation. If speed of job, food & length of job is known as J.C. Time taken
for complete cut-
= 1 min
=sxn

Where,
s = feed per revolution
n = No. of revolution / min of job
l = Length of job to be machined
∑ Shaping operation :
If length of cutting stokes, breadth of job feed & cutting speed are known
time required to complete job may be calculated as;
T = L X B (1 + m)/1000 R V x S.
Where,
T = Total time taken to complete cut.
L = length of stoke in mm
R = The ratio of return time to cutting time
V = The cutting speed expressed in m/min
S = Feed expressed in mm/per double stroke
∑ Milling operation :
Time required to mill any component surface can be given as,
T = A/(sz x z x n)
Where,
T = Time required to complete cut in min
L = Length of table travel to complete cut in mm
SZ = Feed per tooth in mm
Z = No. of teeth of cutter
n = No. of revolutions of cutter per minute

∑ Drilling operation :
Machining time in drilling operation can be determined by formula.
T = 1/sr × n mm.
Where,
T = Machining time in min.
l = Length of travel of drill per min.
n = No. of revolutions of drill in mm.
sr = Feed per revolution of drill in mm.
∑ Grinding operations :
Time taken for grinding operation is given by,
T = li/(sd × np × k)
Where,
li = Length of longitudinal travel
sd = Longitudinal feed in mm/revolutions
np = Speed of workpiece in rpm.
k = Coefficient depending on the specific grade of accuracy & class
of surface finished (K = 1.3 to 1.7)

14.4. TIME REQUIRED FOR MACHINING TIME COMPONENTS
1) Frame
Angle measuring = 30 min
Angle cutting = 45 min
Welding = 120 min
Total time = 195 min
2) Bearing
Facing = 20 min
Turning = 25 min
Drilling = 10 min + 20 min = 30 min
Boring = 20 min
Total time = 95 min
3) Shaft
Facing = 20 min + 20 min = 40 min
Turning = 60 min + 60 min = 120 min
Total time = 160 min
4) Plywood Ramp
Cutting = 30 min
Drilling = 30 min
Total time = 60 min

5) Flywheel
Cutting = 15 min
Milling =180 min
Boring = 40 min
Total time =235 min
6) Acrylic Sheet Casing

Cutting = 60min
Drilling = 25 min
Total time = 85 min
7) Gearbox Stand
Cutting = 20 min
Grinding = 25 min
Welding = 20 min
Total time = 65 min

15. APPLICATION
For a vehicular flow of 40-400 per day, which includes two wheelers, the
energy produced will be much more significant compared to the experimental
results obtained, thus making it a good energy producing setup as energy of
vehicles on impact with the speed breakers is anyway lost. This is lost to heat
and sound. This energy can be tapped, stored and used as back up or for small
applications. Improvements have to be made in the setup to increase the
efficiency which is discussed in following section. In this study a new technique
has been proposed to gate electricity from speed breakers. This technique will
help to conserve our natural resources.
∑ This technique can be used in all highways at Toll plaza where speed
breaker is more in quantity.
∑ For rural area near highways, Road signal, street lights, sign boards.
∑ Lightning of Bus stops, check posts, parking lots.

16. 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.
∑ It’s an Eco-friendly and Green system.
∑ This mechanism can be made in a very economical price
∑ Heat generated is less due nylon gears.
∑ It will work with light weight and heavy vehicle.
∑ Standard materials are used which are readily available in the market.
.
DISADVANTAGE
o We have to check mechanism from time to time.
o To get higher output we need to choose materials which can bare
higher loads.

1] Time period Vs number of vehicles
2] Pie chart of Power Generation in India

3] Electricity generated Vs Number of vehicles
ELECTRICITY GENERATED(watt)
6000
Electricity Generated (Watts)
5000
4000
3000
ELECTRICITY
2000 GENERATED(watt)
1000
0
0 500 1000 1500 2000 2500 3000 3500
Number Of Vehicles
4] Number of vehicles Vs Years

Increase in vehicles per year

35
30
No.of vehicles(lakhs)
25
20
15
10
0
2011 2012 2013 2014 2015
Years
5] Load Vs Voltage Produced
10
9
8
Voltage Produced (V)
7
6
5
4
3
2
1
0
60 100 140 180
Load (Kg)

6] Voltage Vs Speed
Voltage Vs Speed
9
6
Voltage (v)
0
10 20 30 40
Speed (Km/hr)
17. FUTURE SCOPE
In the current model, the speed breaker is made up of PVC pipe which cannot
be actually used. It can be replaced with hard plastic with a coarse texture to
provide better grip between the tires and the rollers.
The gear drive will be replaced with a V-belt drive. This would reduce the
shocks and vibration caused when under heavy load. Also Belt drives do not
require lubrication which would decrease maintenance costs and for rack and
pinion which cannot be replaced with belt drive we will use c-64 material.
Ferrium C64 (AMS 6509) is a new high strength, high surface hardness, good
fracture toughness carburizable steel that also has high temperature resistance,

corrosion resistance and hardenability. C64 steel is a higher performance

upgrade from 9310, X53 (AMS 6308), EN36A, EN36B, EN36C and 8620. It
can achieve a surface hardness of 62-64 Rockwell C (HRC) via vacuum
carburization.
C64 steel is double vacuum melted (i.e., vacuum induction melted and then
vacuum arc re-melted or "VIM/VAR") so that it is very clean, which helps it
have a much greater fatigue strength.
RACK AND PINION

∑ The bearings can be replaced with more durable Plummer bearings reducing
the chance of failure.
∑ The material of the rollers can be made lighter so as to increase the

efficiency. The mild steel used in this model can be replaced by
aluminum alloy 6063 or 6061.
∑ 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.
The mass of any vehicle travelling over the speed breaker = 300Kg
(Approximately)
Height of speed brake = 15 cm.

Work done = weight of the body x distance travelled by the vehicle.

Here, Weight of the Body = 300 Kg x 9.81 = 2943 N.
Distance traveled by the body = Height of the speed breaker = 15cm.
Power = Work done/Second = (2943 x 0.15)/60 = 7.3575 Watts.
Output Power developed for 1 vehicle passing over the speed.
Breaker arrangement for one minute = 7.3575 Watts.
Power developed for 60 minutes (1 hr.) = 441.45 Watts.
Power developed for 24 hours = 10.5948 Kw.
This power generated by can be used for any applications.

18. PREACUTIONS & SAFETY MEASURES

Following precautions and safety measures are taken to make our creation a
grand success.
18.1. PRECAUTION
1) The spring tension in the top plate of speed breaker plate should be
adjusted uniformly
2) The alignment of rack and pinion arrangement should be properly done.
3) Do not allow the vehicle to stop on the speed breaker
4) The system should be robustly designed.
18.2. SAFETY MEASURES

1) Do not touch the top plate when the vehicle is passing by.
2) Do not touch the open wires of the transmission system.

19. REFERENCES
[1]. Alok Kumar Singh, Deepak Singh, Madhawendra Kumar, Vijay Pandit,
Generation of Electricity through Speed Breaker Mechanism; International
Journal of Innovations in Engineering and Technology (IJIET) 2(2), 2013,
20-24.
[2]. Aswathaman. V, Priyadharshini.M, Every Speed Breaker Is Now A Source
of Power; International Conference on Biology, Environment and Chemistry
(IPCBEE), 1, 2011, 234 - 236.
[3]. Shakun Srivastava , Ankit Asthana, Produce electricity by the use of speed
Breakers; Journal of Engineering Research and Studies , 2(1), 2011, 163 –
165.
[4]. Ankit Gupta, Kuldeep Chaudhary & B.N Agrawal, An Experimental study
of Generation of Electricity using Speed Breaker, International Journal of
Mechanical Engineering (IJME ), 1(1), 2012, 35-40.
[5]. Noor Fatima ,Jiyaul Mustafa, Production of electricity by the method of
road power generation, International Journal of Advances in Electrical and
Electronics Engineering, 1(1), 9-14.
[6]. Ankita, Meenu Bala, Power generation from speed breaker, International
Journal of Advance Research in Science and Engineering (IJARSE), 2 (2),
2013.
[7]. Jesse Pinkman, System of Genreating Electricity; Patent publication No.
WO 2013011519 A1, 2013.
[8]. Aniket Mishra, Pratik Kale, Atul Kamble, Electricity Generation from
Speed Breakers, The International Journal Of Engineering And Science
(IJES), 2(11), 2013, 25 – 27.

[9].IRC86, Geometric Design Standards for Urban Roads in Plains, Indian

Roads Congress, 1991.
[10].P.M. Anderson and A.A. Fouad, “Power System Control & Stability”,
Galgotia Publication.
[11].Watts. “Effects of speed distribution on the Harmonies model predictions”,
Inter-noise Conference, Prague, 2004.
[12]. http://www.docstoc.com/docs/20078694/POWER-HUMP
[13]. http://www.iitg.ac.in
[14]. http://www.scribd.com/doc/29409954/POWER-GENERATION-USING-
SPEED-BREAKERS, retrieved on 22-02-2012

ASSEMBLY
SPUR GEAR SPUR GEAR

SPUR GEAR
SHAFT SUPPORT SPROCKET
SPEED
RACK
UNI DIRECTIONAL BEARING

DYNAMO
HELICAL SPUR GEAR

PHOTOS

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Maharashtra Institute of Technology, Pune Page 1

SR.NO. NAME THE TOPICS PAGE

6.2. Making Electricity 13

6.4. Speed Breaker Specifications 22

6.5. Materials for Speed Breakers 23

7.1. Energy Transformation 26

7.2. Main Components 26

8.0 WORKING PRINCIPLE 32

9.1. Material Selection Factors 34

9.2. Material Properties 34

9.3. Materials Used 38

Maharashtra Institute of Technology, Pune Page 2

11.1. Design of transmission system 50

11.2. Torque induced on shaft 51

11.3. Design of Spur gear 52

11.4. Design of spring 55

11.5. Design of fillet welded joints 58

14.0 TIME ACCOUNTING 62

14.1. Machine time estimation 62

14.2. Procedure for calculating machining time 62

14.3. Time analysis 63

14.4. Time Required for Machining time components 66

16.0 ADVANTAGES AND DISADVANTAGES 69

17.0 FUTURE SCOPE 73

18.0 PRECAUTIONS & SAFETY MEASURES 77

18.2. Safety Measures 77

20.0 PHOTOS AND ASEEMBLY 80-81

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For reduction of carbon dioxide emission, renewable energies are considered as

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To produce energy with the help of speed-breaker mechanism by using most

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∑ Low budget electricity generation.

Maharashtra Institute of Technology, Pune Page 9

An engineer is always focused towards challenges of bringing ideas and

In the age of automation machine become an integral part of human being. By

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Thus we selected kinetic generator means the “Energy in motion when it is

AVAILABLE FLEXIBLE POWER

FIG 1: the set up flow diagram

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6.1 WHAT IS ELECTRICITY?

Electricity is a form of energy. Electricity is the flow of electrons. All matter is

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6.2. MAKING ELECTRICITY

Electricity can be made or generated by moving a wire (conductor) through a

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6.3. ELECTRICITY FROM A SPEED BREAKER

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6.4. SPEED BREAKER SPECIFICATIONS

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