DESIGN AND FABRICATION OF

LEVANT SHOCK ENERGY

A PROJECT REPORT

Submitted by

T.SATHISH KUMAR (41908114313)

K.VENKAT BALAJI (41908114015)

M.C.SAREN JEYAKUMAR (41908114035)

ABHIMENYU (41908114002)

In partial fulfillment for the award of the degree

Of
BACHELOR OF ENGINEERING
In
MECHANICAL ENGINEERING

SRI SAI RAM ENGINEERING COLLEGE, CHENNAI - 600 044

ANNA UNIVERSITY: CHENNAI - 600 025
APRIL 2011
 ANNA UNIVERSITY: CHENNAI 600 025

BONAFIDE CERTIFICATE

Certified that this project report on “DESIGN AND FABRICATION OF

LEVANT SHOCK ENERGY” is the Bonafide work of

T.SATHISH KUMAR (41908114313)

K.VENKAT BALAJI (41908114015)

M.C.SAREN JEYAKUMAR (41908114035)

ABHIMENYU (41908114002)

Who carried out the project work under my supervision.

SIGNATURE SIGNATURE

Dr.A.RAJENDRAPRASAD Mr.PANDIARAJAN
DEAN- R&D LECTURER
HEAD OF THE DEPARTMENT SUPERVISOR
Mechanical Engineering Mechanical Engineering
Sri Sairam Engineering College Sri Sairam Engineering College
Sai Leo Nagar, West Tambaram, Sai Leo Nagar,West Tambaram
Chennai -600 044. Chennai – 600 004.

Submitted for viva-voce held on

Internal Examiner External Examiner

 ACKNOWLEDGEMENT

We express our sincere thanks to our chairman Thiru. MJF.Ln.LEO MUTHU,

Our director Prof.V.R.RAJAMANICKAM, our CEO Mr.SAI PRAKASH LEO MUTHU
SRI SAI RAM ENGINEERING COLLEGE , for their kind attention and valuable

suggestions given to me throughout the course.

We are deeply indebted to our Principal Prof.Dr.C.V.JAYAKUMAR, for being

a source of inspiration throughout my study in this College.

We thank our Head of the Department Dr.A.RAJENDRA PRASAD, Project

Co-coordinator Mr.ASHOK GANDHI for their support and our staffs for their
guidance and encouragement at each and every stage of our project work and also
guiding us properly throughout the reviews.

With profound respect, we express our deep sense of gratitude and sincere
thanks to Mr.PONRAJ (R&D ALFO ELECTRICALS) and Mr.JAGANNATHAN (HR-
ERIEZ MAGNETICS INDIA PVT.LIMITED), for his valuable guidance and

suggestions and support.

Finally our hearty respect and gratitude towards Mr.PANDIARAJAN who has
been our internal guide in making this project successful and being with us
throughout the progress of the project.

We take this opportunity to extend our thanks to all persons who have
directly or indirectly helped us in the progress of the project.
 ABSTRACT

Shock absorbers are the mechanical device that absorbs or dampens

shock impulse and dissipate kinetic energy. Shock absorbers are a significant
part of automobile and motorcycle suspensions. The shock absorbers duty is
to absorb or dissipate energy.

Whenever the vehicle moves in ups and downs, the piston in the
shock absorber being the heart of the device also moves up and down which
is said that the shock absorber has absorbed the vibration and the passengers
feel the comfort during the ride.

The main idea of the project is to make use of this to and fro motion
of the piston and convert it into some useful form of energy other than
wasting it without disturbing the damping facility that is been provided in
the shock absorbers .

The useful form of energy that is been obtained from the motion of
the piston is ELECTRICAL ENERGY by using the principle of Faraday’s
Law of Electromagnetic Induction (i.e. by using the magnet and copper
coil as the major elements).

The power that is generated in this mechanism is further converted

into DC by using a bridge rectifier and makes use this power supply for
charging the battery of the mobile.

Hence the concept of the project is deeply explained below with also
their limitations involved in using it.
 CONTENTS

CHAPTER TITLE PAGE NO

ACKNOWLEDGEMENT i
ABSTRACT ii
LIST OF TABLES iii
LIST OF FIGURES iv

1 INTRODUCTION

2 ELECTRICAL CONCEPTS AND LAWS

2.1 SI units based upon the magnetic properties

Of electric currents.
2.2 Joules law
2.3 Ohms law
2.4 Properties of the magnet
2.5 Coulomb s law
2.6 Electrical field
2.7 Electrical intensity
2.8 Electrical flux
2.9 Law of electromagnetic induction
2.10 Faraday s law of electromagnetic induction
2.11 Lenz s law of electromagnetic induction

FARADAY LAW
 LENZS LAW

MAGNET AND COIL

3 MECHANICAL CONCEPTS

3.1 Shock absorbers

3.2 Types of shock absorbers
3.3 Purpose of shock absorbers
3.4 Suspension system
3.5 Components of suspension system
3.6 Functions of suspension system
3.7 Principles of suspension system
3.8 Basic suspension movements
3.9 Types of suspension springs
3.10 Types of suspension system

4. COMPARISON SPECIFIC CHART FOR

VARIOUS INDUSTRIAL PLASTICS

5. DESIGN AND FABRICATION

5.1Design of shock absorber

5.2Working principle
5.3Modifications done
5.4Experiments conducted
5.5Further progress on the project

6 COST ESTIMATION
 7 CONCLUSION

8 BIBLIOGRAPHY

LIST OF TABLES

1. SI electromagnetism units

2. Comparison chart of various industrial plastics

LIST OF FIGURES

1. Faradays law
2. Lenzs law
3. Magnet and coil
4. Shock absorber
5. Types of shock absorber

PROJECT PHOTOS:

INTRODUCTION
SHOCK ABSORBERS:

 Shock absorber, device for reducing the effect of a sudden shock by the
dissipation of the shock energy.
 When the wheels hit a hole or a raised spot on a road, the springs absorb the
resultant shock by expanding and contracting.
 To prevent the springs from shaking the frame excessively, their motion is
restrained by shock absorbers, which are also known by the more descriptive
term dampers.
 In order for a spring to expand and contract, it must pull apart and push
together the ends of this shock absorber.

PRINCIPLE:
“Faradays law of electromagnetic induction.”

MAGNET AND COIL:

When a magnet is moved into a coil of wire, changing the magnetic field and
magnetic flux through the coil, a voltage will be generated in the coil according to
Faraday's Law When a magnet is moved into a coil of wire, changing the magnetic
field and magnetic flux through the coil, a voltage will be generated in the coil
according to Faraday's Law.

When the magnet is moved into the coil the measuring meter deflects to the
left in response to the increasing field.
 When the magnet is pulled back out, the measuring meter deflects to the
right in response to the decreasing field. The polarity of the induced EMF is such
that it produces a current whose magnetic field opposes the change that produces
it.

PROJECT IDEA:

The main idea of the project is to make use of this to and fro motion of the
piston and convert it into some useful form of energy other than wasting it
without disturbing the damping facility that is been provided in the shock
absorbers .
The useful form of energy that is been obtained from the motion of the
piston is ELECTRICAL ENERGY by using the principle of Faraday’s Law of
Electromagnetic Induction (i.e. by using the magnet and copper coil as the major
elements).
The power that is generated in this mechanism is generally AC and hence it
is further converted into DC by using a bridge rectifier and makes use this power
supply for charging the battery of the mobile.
For charging the mobile we require just a voltage of 3.5v to a max of 3.8v
which can be easily obtained in this methodology of the project.
Hence for carrying out this project certain modifications have been done
which is discussed in detail below.
 ELECTRICAL CONCEPTS

UNITS:

Electromagnetic units are part of a system of electrical units based primarily upon

the magnetic properties of electric currents, the fundamental SI unit being the
ampere. The units are:

 Ampere (current).

 Coulomb (charge).

 Farad (capacitance).

 Henry (inductance).

 Ohm (resistance).

 Volt (electric potential).

 Watt (power).

 Tesla (magnetic field).

 Weber (flux).

These are some of the electromagnetic units that should be known before the
different electrical or magnetic properties and their fundamental data’s are studied
in detail.
SI electromagnetism units
Symbol Name of Quantity Derived Units Unit Base Units
ampere (SI base
I Electric current A A (= W/V = C/s)
unit)
Q Electric charge coulomb C A·s
U, ΔV, Potential
volt V J/C = kg·m2·s−3·A−1
Δφ; E difference; Electromotive force
Electric V/A =
R; Z; X ohm Ω
resistance; Impedance; Reactance kg·m2·s−3·A−2
ρ Resistivity ohm metre Ω·m kg·m3·s−3·A−2
P Electric power watt W V·A = kg·m2·s−3
C/V =
C Capacitance farad F
kg−1·m−2·A2·s4
E Electric field strength volt per metre V/m N/C = kg·m·A−1·s−3
Coulomb per
D Electric displacement field C/m2 A·s·m−2
square metre
ε Permittivity farad per metre F/m kg−1·m−3·A2·s4
χe Electric susceptibility (dimensionless) - -
Conductance; Admittance; Susce Ω−1 =
G; Y; B Siemens S
ptance kg−1·m−2·s3·A2
siemens per
κ, γ, σ Conductivity S/m kg−1·m−3·s3·A2
metre
Wb/m2 =
Magnetic flux density, Magnetic
B tesla T kg·s−2·A−1 =
induction
N·A−1·m−1
Φ Magnetic flux Weber Wb V·s = kg·m2·s−2·A−1
ampere per
H Magnetic field strength A/m A·m−1
meter
Wb/A = V·s/A =
L, M Inductance Henry H
kg·m2·s−2·A−2
μ Permeability Henry per metre H/m kg·m·s−2·A−2
χ Magnetic susceptibility (Unit less) - -
 TABLE NO.1
JOULES LAW:

INTRODUCTION:
                                            

When an electric current passes through wire heat energy is produced. It

is due to the collision of electrons with the atoms. In order to continue steady
current, work has to be done on electric charges.
  
STATEMENT:

     Amount of work done on electric charge on steady current is directly

proportional to amount of heat
.
Work Heat

    PROOF:     Consider a conductor through which electric current q is passing in

time t let the potential difference     between two ends of wire is V.    

 We know that

v = W/q
(or)
W=qxV (i)

According to Ohm’s law V = IR

Putting the value of V in equation (i)

W = q x IR (ii)

But

I = q/t
(Or)
Q = It

    Putting the value of Q in equation (ii)

W = It. IR

W = I2Rt
 OHMS LAW

INTRODUCTION:
     Ohm’s law is a quantitative relation b/w potential difference and
electric current.

STATEMENT:

      According to Ohm’s law,

"The electric current passes through a conductor is directly proportional

to the potential differences between the ends of conductor,
if physical conditions of conductor remain constant."

    i.e.
IV

I = kV

    K =constant and is called "conductivity of material"

I/K = V
or
V = I/K

V = I x 1/K
Let [1/K = resistance]

V=IxR

GRAPHICAL REPRESENTATION
Galvanometer:
Galvanometer is an electromechanical instrument which is used for the
detection of electric currents     through a circuit. Being a sensitive instrument,
Galvanometer cannot be used for the measurement of     heavy currents.

AMMETER:
Ammeter is an electrical measuring device, which is used to measure electric
current through the circuit.

Connection of Ammeter in Circuit:

An ammeter is always connected in series to a circuit.

VOLTMETER:
Voltmeter is an electrical measuring device, which is used to measure
potential difference between two points in a circuit.

Connection of Voltmeter in Circuit:

Voltmeter is always connected in parallel to a circuit.

PROPERTIES OF MAGNET:

1. Magnets attract objects of iron, cobalt and nickel.

    2. The force of attraction of a magnet is greater at its poles than in the middle.
    3. Like poles of two magnets repel each other.
    4. Opposite poles of two magnets attracts each other.
    5. If a bar magnet is suspended by a thread and if it is free to rotate, its South
Pole will move towards     the North Pole of the earth and vice versa.
CHARACTERISTICS OF MAGNETIC LINES OF FORCE:

 1. Magnetic lines of force start from the North Pole and end at the South Pole.
    2. They are continuous through the body of magnet
    3. Magnetic lines of force can pass through iron more easily than air.
    4. Two magnetic lines of force cannot intersect each other.
    5. They tend to contract longitudinally.
    6. They tend to expand laterally.

FERROMAGNETIC SUBSTANCES:
Substances that behave like a magnet in the presence of a magnetic field are
known as Ferromagnetic Substances.

    EXAMPLES: Iron, cobalt and nickel are ferromagnetic substances.

LAW OF CONSERVATION OF ENERGY:

According to the law of conservation of energy:

                       "Energy can neither be created nor it is destroyed, however
energy can be converted from one form energy to any other form of energy"

COULOMB'S LAW:
The magnitude of the force of attraction or repulsion between two electric
charges at rest was studied by Charles Coulomb. He formulated a law, known as
"COULOMB'S LAW".
According to Coulomb's law:

1.The electrostatic force of attraction or repulsion between two point charges

is directly proportional to the product of charges.

2. The electrostatic force of attraction or repulsion between two point charges

is inversely proportional to the square of distance between them.

ELECTRIC FIELD:

When an electric charge is placed in space, the space around the charge is modified
and if we place another test charge within this space, the test charge will
experience some electrostatic force. The modified space around an electric charge
is called 'ELECTRIC FIELD'. For an exact definition we can describe an electric
field as:
Space or region surrounding an electric charge or a charged body within
which another charge experiences some electrostatic force of attraction
or repulsion when placed at a point is called Electric Field.
ELECTRIC INTENSITY:

Electric intensity is the strength of electric field at a point.

Electric intensity at a point is defined as the force experienced
per unit positive charge at a point placed in the electric field.
(OR)
It may also be also defined as the electrostatic force per unit
charge which the field exerts at a point.

Mathematically,

E=F/q

Electric Line Of Force:

An electric line of force is an imaginary continuous line or curve drawn in

an electric field such that tangent to it at any point gives the direction of the
electric force at that point. The direction of a line of force is the direction along
which a small free positive charge will move along the line. It is always directed
from positive charge to negative charge.
ELECTRIC FLUX:

Electric flux is defined as:

"The total number of lines of force passing through the unit area of a surface
held perpendicularly."

"The dot product of electric field intensity (E) and the vector area (∆A) is
called electric flux."  

Where Ө is the angle between E and ∆A

MAXIMUM FLUX:

If the surface is placed perpendicular to the electric field then maximum electric
lines of force will pass through the surface. Consequently maximum electric flux
will pass through the surface.

 
ZERO FLUX:

If the surface is placed parallel to the electric field then no electric lines of
force will pass through the surface. Consequently no electric flux will pass through
the surface.  

MAGNETIC FLUX:
Magnetic flux ()) is equal to total number of magnetic lines of force
passing through an area ‘A’ of any shape.

Unit of magnetic flux is WEBER.

FLUX DENSITY:

 It is the number of magnetic lines of force passing through unit area of a surface.
It is denoted by     (B). Flux through an area A is given by.

Unit of B is Weber/m2 or Tesla.

ELECTRO MAGNETIC INDUCTION-“LAWS OF ELECTRO MAGNETIC
INDUCTION:”

  In 1830 Joseph Henry and Faraday observed that an E.M.F. is setup in a coil
placed in a magnetic field whenever the flux through the coil changes. This effect
is called Electromagnetic Induction.

    If the coil forms a part of a close circuit, the E.M.F. causes a current to flow
in the circuit. E.M.F. setup in the coil is called "induced E.M.F" and the current
thus produced is termed as "Induced Current".

   Experiments show that the magnitude of E.M.F. depends on the rate at which the
flux through the coil changes. It also depends on the number of turns on the coil.

   There are various ways to change magnetic flux of a coil such as;

   (1) By changing the relative position of the coil with respect to a magnet.

   (2) By changing current in the coil itself.

   (3) By changing current in the neighboring coil.

   (4) By changing area of a coil placed in the magnetic field etc.

FARADAY S LAW OF ELECTROMAGNETIC INDUCTION:

Faraday was the first scientist who performed a number of experiments to

discover the facts and    figures of electromagnetic induction, he formulated the
following law:
   “When magnetic flux changes through a circuit, an EMF is induced in it
which lasts only as long as the change in the magnetic flux through the circuit
continues.”

   Quantitatively, induced EMF is directly proportional to the rate of change of

magnetic flux through the coil.

i.e.  

Average EMF = = -N/t

                  Where N = number of turns in the coil.

   The negative sign indicates that the induced current is such that the magnetic
field due to it opposes    the magnetic flux producing it.

LENZ S LAW:

Lenz’s law in fact describes that in order to produce an induced EMF or induced
current some external    source of energy must be supplied otherwise no current
will induce.

Lenz’s law states that"

   "The direction of induced current is always such as to oppose the cause

which produces it".

   That is why a –ve sign is used in Faraday’s law.

 FARADAY'S LAW

Any change in the magnetic environment of a coil of wire will cause a

voltage (EMF) to be "induced" in the coil. No matter how the change is produced,
the voltage will be generated. The change could be produced by changing the
magnetic field strength, moving a magnet toward or away from the coil, moving
the coil into or out of the magnetic field, rotating the coil relative to the magnet,
etc.

Faraday's law is a fundamental relationship which comes from Maxwell's

equations. It serves as a succinct summary of the ways a voltage (or EMF) may be
generated by a changing magnetic environment. The induced EMF in a coil is
equal to the negative of the rate of change of magnetic flux times the number of
turns in the coil. It involves the interaction of charge with magnetic field.
 LENZ'S LAW

When an EMF is generated by a change in magnetic flux according to

Faraday's Law, the polarity of the induced EMF is such that it produces a current
whose magnetic field opposes the change which produces it. The induced magnetic
field inside any loop of wire always acts to keep the magnetic flux in the loop
constant. In the examples below, if the B field is increasing, the induced field acts
in opposition to it. If it is decreasing, the induced field acts in the direction of the
applied field to try to keep it constant.
 MAGNET AND COIL

When a magnet is moved into a coil of wire, changing the magnetic field and
magnetic flux through the coil, a voltage will be generated in the coil according to
Faraday's Law. In the example shown below, when the magnet is moved into the
coil the galvanometer deflects to the left in response to the increasing field.

When the magnet is pulled back out, the galvanometer deflects to the right
in response to the decreasing field. The polarity of the induced EMF is such that it
produces a current whose magnetic field opposes the change that produces it.

The induced magnetic field inside any loop of wire always acts to keep the
magnetic flux in the loop constant. This inherent behavior of generated magnetic
fields is summarized in Lenz's Law.
 SHOCK ABSORBER:

 Shock absorber, device for reducing the effect of a sudden shock by the
dissipation of the shock energy.
 On an automobile, springs and shock absorbers are mounted between the
wheels and the frame.
 When the wheels hit a hole or a raised spot on a road, the springs absorb the
resultant shock by expanding and contracting.
 To prevent the springs from shaking the frame excessively, their motion is
restrained by shock absorbers, which are also known by the more descriptive
term dampers.
 The type of shock absorber found on automobiles is usually a hydraulic type
that has a casing consisting of two tubes, one telescoping into the other.
 In order for a spring to expand and contract, it must pull apart and push
together the ends of this shock absorber.
 But the ends offer so much resistance that the motion of the spring quickly
dies out.
 The ends are connected to a piston in an oil-filled chamber in the shock
absorbers inner tube.
 The piston can only move if it forces oil past it through valves. This
arrangement creates a large resistance to any motion by the piston and
consequently by the ends.
 On some automobiles a type of hydraulic suspension is used to function both
as a spring and as a shock absorber.
 It comprises a sealed spherical container filled with equal volumes of
hydraulic fluid and gas under pressure.
 The compression of the gas, which absorbs the shock, is supplied by the
vehicle's engine. Shock absorbers are used on aircraft to ease the impact upon
landing.
 Some machines are mounted on resilient materials composed, e.g., of cork or
rubber. The materials act as shock absorbers, isolating the vibrations of the
machine from the surrounding area.

SHOCK ABSORBER
 TYPES OF SHOCK ABSORBER:

Types of shock absorber:

1. Mechanical shock absorber

2. Hydraulic shock absorber

Again the hydraulic shock absorber s are further divided into

1. Van type
2. Piston type
a. Single acting
b.Double acting

3. Telescopic type.
PURPOSE OF SHOCK ABSORBER:

 To control the vibrations on springs.

 To provide comfortable ride
 To act flexible and to be rigid enough
 To resist the unnecessary motion of the springs.

SUSPENSION SYSTEM:

The chassis of the vehicle is connected to the front and rear wheel through
the medium of springs, shock absorbers and axles. All the parts perform the
function of parts from shocks are known as suspension system.

The automobile chassis is connected with the axles indirectly by springs. It

is done to prevent the vehicle body from the road shocks due to form of bounce,
pitch, roll or sway.

It provides an uncomfortable ride and also additional stress in the

automobile frame and body. Both the springing device used and various mountings
are included.

Suspension system has a spring and a damper. The energy of the road shock
produced by the spring oscillates. These oscillations are arrested by the damper
known as a shock absorber.
COMPONENTS OF SUSPENSION SYSTEM:

 Spring to neutralize the shocks from the road surface.

 Dampers called shock absorbers to improve riding comfort by limiting the

free oscillation of the springs.

 Stabilizer called sway bar or anti roll bar to prevent lateral swaying of the
car.

 A linkage system holds the above components to control the longitudinal

and lateral movements of the wheels.

FUNCTIONS OR OBJECTIVES OF SUSPENSION SYSTEM:

 To eliminate the road shocks from transmission to the vehicle components.

 To maintain stability of the vehicle in pitching or rolling while in motion.

 To safe guard the occupants from road shocks.

 To keep the body perfectly in level while travelling over rough uneven
ground.i.e the up and down movement of the wheels should be relative to the
body.

 To minimize the effects of stresses due to road shocks on the mechanism of

the motor vehicle and giving cushioning effect.

 To safe guard the occupants from road shocks and provide riding comfort.
  It supports the body on the axles and keeps the proper geometrical
relationship between the body and wheels.

PRINCIPLES OF SUSPENSION SYSTEM:

 The weight of the wheels.

 Reduction of rolling or pitching of the body to a minimum design and

attachment of the springs.

 Absorbing satisfactorily larger and also the smaller road impacts with the
help of a single springing device.

BASIC SUSPENSION MOVEMENTS:

 Bouncing
 Pitching
 Rolling
 Yawing

TYPES OF SUSPENSION SPRINGS:

1. Steel Springs

 Leaf springs
 Coil springs
  Torsion springs
 Tapered leaf springs

2. Rubber Springs

 Compression springs
 Compression – shear sprig
 Steel reinforced spring
 Progressive spring
 Face shear spring
3. Air Springs

Bellow type springs

Piston type springs

4. Platic springs

5. Air springs

TYPES OF LEAF SPRINGS:

 Semi elliptical springs.

 Quarter elliptical springs.
 Three quarter elliptical springs
 Transverse springs
 Full elliptical springs
  Platform type springs

TYPES OF SUSPENSION SYSTEM:

Front End Suspension.

 Independent Front End Suspension

 Rigid axle Front End Suspension

Rear End Suspension.

 Longitudinal leaf spring Rear end suspension.

 Transverse leaf spring Rear end suspension.

 Coil spring Rear end suspension.

COMPARATIVE SPECIFICATION CHART FOR VARIOUS
INDUSTRIAL PLASTICS:
PROPERTY Test Units Nylon- Delrin/ac Polypropyle Acrylic
method 6 etal ne
ASTM
MECHANICAL
Tensile strength D638 Kg/cm2 580 740 350 730
Elongation at D638 % 100 60 200-700 4.0
break
Flexural modulus D790 Kg/cm3 1.8 2.6 1.8 32(ICI
10^4 test)
Impact strength D256 Ft./lb./.in 1-3.6 1.2-1.6 5-2.0 1.0
(IZOD)
Rockwell D760 “M” scale M-70 MBO _ M102
hardness “R”scale _ R-95 _

THERMAL
Thermal D695 Cm/cm/ 7-10 9-5 11.0 8.8
expansion*10^5 degree c
Resistance to heat 90 110 105 95
continuous degree c
Intermittent Degree c 130 140 150

ELECRICAL
Volume D257 Ohm cm 10^14- 2.5*10^1 10^18 10^14
resistivity 10^15 4
Dielectric D149 V/ml 300- 500 450-600 400
Strength 480
Power factor @60 D150 _ -01 002-003 0.0005 _
cycle
@10^6 cycle _ _ .04 .006 0.0005 _
OTHER
PROPERTIES
Specific gravity D790 _ 1.14 1.41 0.90 1.18
Water absorption D570 % 1-3.5% 0.22 0.02 0.3
24hrs
Burning ratio D625 Cm/min Self Slow(2.7) slow 3.5
ext
CO-EFFICIENT
OF FRICTION
Plastic on steel _ _ 0.11 _ 0.25 _
Steel on plastic _ _ 0.2 _ 0.35 _
RESISTANCE
CHARACTERI
STICS
1.Effect to weak D543 - E F E E
acids
2.Effect of strong D543 - A A E E
acids
3. Effect of weak D543 - E E E E
alkalies
4.Effect of strong D543 - E E E A
alkalies
5. effect of D543 - E E G 80c Soluble
organic solvents in
ketones
6. Resistance to D543 - E G G Soluble
oil in
ketones

Note:
A - ATTACKED DONOT USE
G - GOOD RESISTANCE
E - EXCELLENT RESISTANCE
TESTING ATMOSPHERIC TEMPERATURE-230°C DH-50%

DESIGN AND FABRICATION:

Design of shock absorber:

WORKING PRINCIPLE:

 The project woks under the principle of “Faradays law of electromagnetic

induction.”
 The shock absorber is designed as per the existing model shown in figure
above.
 The copper coil is designed as per the following specifications
 The diameter of the coil.
 Number of turns of the coil.
 A permanent magnet with high polarities and characteristics and properties
that a magnet should have is used.
 The spring of high tension and non-attracting material such as stainless steel
or any other material is made used.

 The copper coil is designed as per the following specifications as mentioned

above and it is wound on a material (the material used here is pp-
polypropylene machined as per the design) and it is placed inside the shock
absorber that is designed.
 The piston of the shock absorber is replaced by the permanent magnet that is
fitted to the stem of the shock absorber piston. The stem is made out of the
nylon material.
 Now whenever the vehicle moves in ups and downs, the magnet which is
fitted to the piston stem gets compressed along with the spring in such a way
that it moves inside the copper coil that is placed in the shock absorber and
once the load is removed it retains the original position by the help of the
spring action.

 When a magnet is moved into a coil of wire(copper wire coil), it changes the
magnetic field and magnetic flux through the coil, a voltage will be
generated in the coil according to Faraday's Law. When the magnet is
moved into the coil the measuring device deflects to the left in response to
the increasing field.
  When the magnet is pulled back out, the measuring device deflects to the
right in response to the decreasing field. The polarity of the induced EMF is
such that it produces a current whose magnetic field opposes the change that
produces it.

 Thus the to and fro motion of the piston is converted into electrical energy
and this electrical energy thus produced is AC and hence it is further
converted to DC by using a bridge rectifier.

 The output of the rectifier (direct current) is connected to the mobile battery
charger and is used to charge the mobile.

 The electrical energy can also be used stored in a battery if it is not required
for charging of mobile and hence the battery can be used as a secondary
source for the electrical based equipments when the main battery is down.

 Hence the name “LEVANT” (using wasted energy) is given to the title of
the project and energy thus obtained can be named as a “GREEN
ENERGY.”

MODIFICATIONS DONE:
 The shock absorber is designed as per the existing model shown in figure
above.
 The copper coil is designed as per the following specifications
 The diameter of the coil.
 Number of turns of the coil.
 A permanent magnet with high polarities and characteristics and properties
that a magnet should have is used.
 The spring of high tension and non-attracting material such as stainless steel
or any other material is made used.
 The material used for shock absorbers model are:
Nylon - casing, hub, eye end.
Polypropylene - winding of copper coil wire.

EXPERIMENTS CONDUCTED:

First step:
Material selection selection of what kind of material is suitable
for the shock absorber design keeping in mind about the following aspects.
 Strength of the material.
 Load it has to withstand.
 Should be a non attractive material.
 Manufacturing must be easier as per the design.
 Cost must be low
Second step:
Magnet selection 1.the experiment was conducted with ceramic
magnets but it had some limitations such as
It was not so powerful. And it was not able to
produce the power that we expected.
So we decided to change the magnet.
2. The experiment was conducted by using a
powerful permanent magnet. Thus the magnet
was satisfied as it produced the power that we
expected.
Third step:
 Copper coil 1. First the bobbin for the winding of copper wire
was machined as per the design required by using polypropylene material.
2. Next the copper wire of diameter 1mm was
wound on the PP material of 500 turns and the magnet was moved in and out
which produced a voltage of 0.5v-1v which was measured by using a
multimeter.
3. Next the number of turns of the copper wire was
increased to 1800 turns and when the magnet was moved in and out
produced a voltage of 2.5v-3.2v measured by using a multimeter.
4. Next we decided to further increase the number
of turns and reduce the diameter of the copper wire.
5.Now the diameter of the wire was reduced to
0.5mm and the number of turns was increased to 2000 turns and we obtained
a voltage of 4.1v-6.2v when the magnet was moved in and out the coil.
6. Finally we decided to increase the number of
turns to 4000 of same dia. of copper wire and when the magnet was moved
in and out produced a maximum voltage of 11.2v-12.1v which we felt that it
is sufficient for the charging of battery.

Forth step:
Bridge rectifier it is used to convert the AC that is obtained
from the copper coil into DC which is used for
charging of mobile which required 3.5v-3.8v and
was easily obtained by using the magnet and coil
as specified.
Further progress on the project:
 This project is just an idea that it is possible of producing power from the to
and fro motion of the piston and we proved by getting a model out of that.
But it is not the end to the project as it is not feasible of using this in heavy
vehicles, and our aim is to imply the concept in regular shock absorbers that we
use in our vehicles.
Hence the modifications for further progress on the project are done as given
below.
 The shock absorber is not going to be changed instead a link is
provided in such a way that when the piston moves downwards
(contracts) simultaneously the magnet on the other hand moves upwards
inside the coil arrangement and when the piston moves upwards
(expands) the magnet on the other hand moves downwards inside the
coil arrangement which results in electrical energy. Thus the reducing
the effect of a sudden shock by the dissipation of the shock energy by the
shock energy. On the other hand electrical energy is been produced
constantly.

COST ESTIMATION:
 Sl.no MATERIAL COST OF THE
MATERIAL
1. NYLON 1550/-
MATERIAL
2. MAGNET 750/-
3. SPRING 250/-
4. ELECTRICAL 400/-
EQUIPMENTS
5. MISCELLANEOUS 500/-
EXPENSES

TOTAL COST 3690/-

CONCLUSION:
 DEMAND FOR ENERGY IS INCREASING DAY BY DAY.SO

WE NEED AN ALTERNATIVE SOURCE TO COMPENSATE

THE INCREASING DEMAND OF ENERGY.

 HENCE MAKE SURE THAT WE ARE ABLE TO UTILISE ALL

FORMS OF ENERGY THAT ARE EXISTING IN DIFFERENT

FORMS BY USING SUITABLE DEVICES AND

TECHNIQUES RATHER THAN WASTING THEM.

“SAVE ENERGY AND LIVE AND ENJOY WITH ENERGY”