Generation of electricity through speed breaker mechanism(AVANTHI CLG MAKAVARPALLEM)

Generation of Electricity through Speed Breaker Mechanism
GENERATION OF ELECTRICITY THROUGH SPEED
BREAKER MECHANISM
Department Of Mechanical Engineering
AVANTHI INSTITUTE OF ENGINEERING AND TECHNOLOGY,
MAKAVARPALEM
(A Constituent College of SBTET.)
SESSION 2017
Submitted By
GaneshPillaka batch (14597-M-047, 31, 19, 38, 20)
Project Guide
MRS; Ramakrishna
Assistant Professor, Department of Mechanical Engineering
AVANTHI INSTITUTE OF ENGINEERING AND TECHNOLOGY,
MAKAVARPALEM

As partial fulfillment of the requirements for the
Bachelor’s Degree
In
MECHANICAL ENGINEERING
This report is submitted to
Department of Mechanical Engineering,
Avanthi institute of Engineering and Technology, Makavarpalem
This is declaring that work submitted in this report is my own, and any work that
is not mine has been quoted and acknowledged in the references.
Approved On------------------------------
Internal Examiner: Engr. K Ramakrishna
Signature: -----------------------------------------
External Examiner:
Signature: -------------------------------------------
Department of Mechanical Engineering,
Avanthi institute of Engineering and Technology, Makavarpalem
(A Constituent College of SBTET.)
Generationof Electricity throughSpeedBreaker Mechanism

Dedication
I dedicate this work to my beloved parents for always supporting
me, because they are the driving force in my life and career.
Without their love, none of this would matter. Throughout my
life, they have actively supported me in my determination to find
and realize my potential, and to make this contribution to our
world.

Acknowledgements
Thanks to MOHAN RAO that enabled me to work in this project because without
His approval man can do nothing. After almighty Allah to his prophet,
(Engr. K Ramakrishna), the most perfect an exalted forever source of guidance and
knowledge humanity as a whole.
There are a number of people without whom this project might not have been
written, and to whom I am greatly indebted.
I will forever be thankful to my advisors, Engr. K Ramakrishna for supporting me
during this study. He has provided insightful discussions about the research. His
support and penetrates has allowed me to complete one of my many life goals. I
would also thankful to our Honorable teacher Engr. ESWARA TEJA for guiding
me on all my work and project. I value the guidance that was giving to me.
Regards
GaneshPillaka

Contents
ABSTRACT..........................................................................................
...........................1
Chapter number 1
INTRODUCTION OF THE
PROJECT...............................................................................................3
1.
INTRODUCTION.................................................................................................
............................4
2. SCOPE OF THE
PROJECT............................................................................................................
..4
Chapter number 2
DEMONSTRATION OF
THEPROJECT...........................................................................................5
1. WORKING PRINCIPLE
.................................................................................................................6
2. BLOCK
DIAGRAM...........................................................................................................
...............7
Chapter number 3
CMODELLING, SIMULATION AND
RESULTS..............................................................................8

1. FABRICATION
DETAILS.............................................................................................................
....9
2. FABRICATION MODEL SHOWING INNER
PARTS..................................................................9
3. MATERIALS
USED.................................................................................................................
........10
4.
SPECIFICATIONS.................................................................................................
........................10
5.
ADVANTAGES....................................................................................................
..........................11
6.
DISADVANTAGE.................................................................................................
.........................11
Chapter number 4
ACCESSORIES
REQUIRED..........................................................................................................
.12
1. RACK AND
PINION...............................................................................................................
....13
2.
SPROCKET..........................................................................................................
.........................14
3. DRIVE
ARRANGEMENTS................................................................................................
...........14

4. BEST
ARRANGEMENTS................................................................................................
..............15
5. OTHER ACCEPTABLE
ARRANGEMENTS.................................................................................15
6. LEAST RECOMMENDED
ARRANGEMENTS............................................................................16
7. SPROCKET
DIMENSIONALSPECIFICATIONS.......................................................................17
Chapter number 5
CHAIN
DRIVES...............................................................................................................
................19
1. Chain
Drives................................................................................................................
.................20
2. Chain Drive
Design...............................................................................................................
.......22
3.
Vibrations..........................................................................................................
............................23
4. Avoiding
vibration............................................................................................................
...........24
5. Chain
Types................................................................................................................
...................24

6. Chain
Failures..............................................................................................................
.................26
Chapter number 6
WHEELS AND
SPRINGS.............................................................................................................
...28
1.
Freewheel..........................................................................................................
............................29
2.
Flywheel............................................................................................................
............................30
3.
Springs..............................................................................................................
...........................32
Chapter number 7
DESIGN PARAMETER`S AND
LIMITATION...............................................................38
1. OUTPUT POWER
CALCULATIONS........................................................................................39
2. DESIGN
SPECIFICATIONS.................................................................................................
......41
3. SPROCKET WHEEL AND
CHAIN.............................................................................................41
4.
SPRINGS.............................................................................................................
.........................41

5. SPUR
GEARS................................................................................................................
...............41
COST
ANALYSIS...........................................................................................................
.................42
REFERENCES.......................................................................................................
............................46
ABSTRACT
Man in his lifetime, uses energy in one form or the other. In fact whatever
happens in nature, results, out of the conversion of energy in one form or the
other. The blowing of the wind, the formation of the clouds and the flow of water
are a few examples that stand testimony to this fact. The extensive usage of
energy has resulted in an energy crisis, and there is a need to develop methods of
optimal utilization, which will not only ease the crisis but also preserve the
environment. Energy conservation is the cheapest new source of energy. This
project attempts to show how energy can be tapped and used at a commonly used
system, the generation of electricity through the speed breaker mechanism.
Generation of electricity through the speed breaker mechanism is one of the most
recent power generation concepts. This device converts the kinetic energy of
the vehicles into electric energy by installing movable speed breaker on the
road, it takes the stroke motion of the vehicles and converts it to the rotary
motion by rack and pinion mechanism and it generates the electricity. This project

also explains clearly, the working principle of the designed system, its practical
implementation, and its advantages. Design of each component has been carried
out using standard procedures, and the components have been fabricated and
assembled. A similar model of the system has been modeled using AutoCAD2007.
Practical testing of the system has been done with different loads at different
speeds. The utilization of energy is an indication of the growth of a nation. One
might conclude that to be materially rich and prosperous, a human being needs to
consume more and more energy. And this project is best source of energy that we
get in day to day life.
GENERATION OF ELECTRICITY
THROUGH SPEED BREAKER
MECHANISM

2
Chapter Number 1
Introduction of the project
1. INTRODUCTION
2. SCOPE OF THE PROJECT

3
Chapter Number 1
Introduction of the project
1. INTRODUCTION
2. SCOPE OF THE PROJECT

1.INTRODUCTION:-
This projectattempts to show how energy can be tapped and used at a commonly used
system-theroad speed-breakers. Thenumber 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 modelwe show that how we can generate a voltage fromthe busy
traffic. Conversion of the mechanical energy into electrical energy is widely used concept. It’s a
mechanismto generate power by converting the potential energy generated by a vehicle
going up on a speed breaker into rotational energy. We have used that simple concept to the
project.
2. SCOPE OF THE PROJECT:-
The utilization of energy is an indication of the growth of a nation. For example, World average
per capita electricity consumption is 2730 kWh compared to Pakistan’s per capita electricity
consumption of 451 kWh. Pakistan has an installed electricity generation capacity of
22,797MW. Theaveragedemand is 17,000MW and theshortfallis between 4,000 and
5,000MW. Onemightconclude that to be materially rich and prosperous, a human being
needs to consumemore and more energy. Pakistan is facing serious energy crisis at this time.
Pakistan as third world developing country is lot affected by this energy crisis in the world. The
major issueis electric crisis which is known as load shedding Pakistan’s smallmanufacturing
markets are lot affected by the riseof energy prices.
By just placing a unit like the “Power Generation Unit from Speed Breakers”, so
much of energy can be tapped. This energy can be used for the lights on the
either sides of the

Roads and thus much power that is consumed by these lights can be utilized to send power to
these villages.
4
Chapter Number 2
Demonstration of the Project
1. WORKING PRINCIPLE
2. BLOCK DIAGRAM

5
1.WORKING PRINCIPLE:-
The project is concerned with generation of electricity fromspeed breakers-likesetup. 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 sprocketarrangement.
The sprocketarrangementis made of two sprockets. Oneof larger size and the other of
smaller size(free wheel). Both the sprockets areconnected by means of a chain which serves
in transmitting power fromthe larger sprocketto the smaller sprocket. As the power is
transmitted fromthe larger sprocketto the smaller sprocket, thespeed that is available at the
larger sprocketis relatively multiplied at the rotation of the smaller sprocket. Theaxis of the
smaller sprocketis coupled to a fly wheel. The fly wheel is coupled to the shaft at axis of the
smaller sprocket. Hencethe speed that has been multiplied at the smaller sprocketwheelis
passed on to this flywheelof larger dimension. The smaller sprocketis coupled to the larger fly
wheel. So as the larger fly wheel rotates at the multiplied speed of the smaller sprocket, the
smaller sprocketfollowing the larger sprocketstill multiplies the speed to moreintensity.
Hence, although the speed due to the rotary motion achieved at the larger sprocketwheel is
less, as the power is transmitted to fly wheel, finally the speed is multiplied to a higher speed.
This speed which is sufficientto rotate shaftconnected to generator. The rotor (shaft) rotates
the generator. The generator produces the DCcurrent. This DC currentis now sent to the
storagebattery whereit is stored during the day time. This currentis then utilized in the night
time for lighting purposes on the either sides of the road to a considerable distance.

6
2.BLOCK DIAGRAM:-

7
Chapter Number 3
Modeling, Simulation and
Results
1. FABRICATION DETAILS
2. FABRICATION MODEL SHOWING INNER
PARTS
3. MATERIALS USED
4. SPECIFICATIONS
5. ADVANTAGES
6. DISADVANTAGE

8
1. FABRICATION DETAILS:-
The frame structure for the total unit is fabricated
using L-Angle frames and ordinary frames. These frames are made
of mild steel. They are held to proper dimensions are attached to
form a unit with the help of welding. Then the bearings which are of
standard make are kept in place with the irrespective shafts through
them and are welded to the frame structure. The shafts are also
made of mild steel. Hinges are used to move the speed breaker
arrangement by welding it to the frame structure. These hinges are
responsible for the movement of the speed breaker in an up and
down motion. A rack which is made up of mild steel is welded to the
speed breaker arrangement. A pinion which is also made up of mild
steel and which has Thirty six teeth is fitted on the shaft initially, and
welded. This pinion tooth is exactly made to mate with the teeth of
the rack. A bicycle sprocket and chain arrangement of standard
make is fitted with the larger sprocket on the top shaft and its
smaller sprocket on the bottom shaft. The sprocket wheels are
welded to the shafts. A fly wheel that is made of cast iron is
machined suitably to the precise dimensions in a lathe and is placed

on the shaft with its axis coinciding with the axis of the shaft and is
welded. A special stand arrangement is made to seat the 12v DC
generator using frames. A 12v DC generator is placed within the seat
and is held firm using bolts and nuts.
2. FABRICATION MODEL SHOWING
INNER PARTS:-
Wires are connected to the terminals of the DC generator and its other ends are
connected to a Lead-Acid battery. Another wire is taken from these points on the
battery and its other ends are connected to the
Positive and negative terminal of an inverter. An output wire from the inverter is
sent to the light.
9
3. MATERIALS USED:-
•Rack-Mild steel
•Pinion-Mild Iron
•Sprocket wheels-Mild steel

•Chain-Mild steel
•Spur gears-Cast Iron
•Springs-Mild steel
•Shaft -Mild steel
•Speed breaker -Mild steel
4. SPECIFICATIONS:-
Generator -12v DC generator
Battery -lead acid battery
Inverter -250 w AC inverter
10
ADVANTAGES:-

Pollution free power generation.
Simple construction, mature technology, and easy maintenance.
No manual work necessary during generation.
Energy available all year round.
No fuel transportation problem.
No consumption of any fossil fuel which is non-renewable source of
energy.
Uninterrupted power generation during day and night.
Maximum utilization of energy.
Load to the piston cylinder arrangement is freely got by movement of
vehicles.
No fuel storage is required.
It will work with light weight and heavy vehicle
6. DISADVANTAGE:-
We have to check mechanism from time to time
It can get rusted in rainy season.

11
Chapter Number 4
Rack, Pinion and Sprocket
1. RACK ANDPINION
2. SPROCKET
3. DRIVE ARRANGEMENTS
4. BEST ARRANGEMENTS
5. OTHER ACCEPTABLE ARRANGEMENTS
6. LEAST RECOMMENDED ARRANGEMENTS
7. SPROCKET DIMENSIONAL SPECIFICATIONS

12

1. RACK AND PINION:-
A rack and pinion gears system is composed of two gears. The
normal round gear is the pinion gear and the straight or flat gear is the rack.
A rack and pinion is a type of linear actuator that comprises a
pair of gears which convert rotational motion into linear motion. The circular
pinion engages teeth on a linear "gear" bar which is called the “rack“.

Rotational motion applied to the pinion will cause the rack to move to the
side, up to the limit of its travel.
For example, in a rack railway, the rotation of a pinion mounted on a
locomotive or a railcar engages a rack between the rails and pulls a train along
a steep slope.

The rack and pinion is also used to convert between rotary and linear
motion. The rack is the flat, toothed part, and the pinion is the gear. Rack and
pinion can convert from rotary to linear of from linear to rotary motion.
It converts the linear motion of the speed breaker into the circular motion
needed to turn the shaft.
13
SPROCKET:-
A sprocket or sprocket-wheel is a profiledwheelwithteeth or cogs that mesh
with achain,trackor other perforated or indented material. The name "sprocket"
applies generally to any wheel upon which are radial projections that engage a
chain passing over it. It is distinguished from a gear in that sprockets are
never meshed together directly, and differs from a pulley in that sprockets
have teeth and pulleys are smooth. The word "sprockets" may also be used to
refer to the teeth on the wheel.
Sprockets are used in bicycles, motorcycles, cars, tracked vehicles, chainsaws
and other machinery either to transmit rotary motion between two shafts
where gears are unsuitable or to impart linear motion to a track, tape etc.
Perhaps the most common form of sprocket may be found in the bicycle, in
which the pedal shaft carries a large sprocket-wheel, which drives a chain,
which, in turn, drives a small sprocket on the axle of the rear wheel. Early
automobiles were also largely driven by sprocket and chain mechanism, a
practice largely copied from bicycles.

Sprockets are of various designs, a maximum of efficiency being claimed for
each by its originator. Sprockets typically do not have a flange. Some sprockets
used with timing belts have flanges to keep the timing belt centered. Sprockets
and chains are also used for power transmission from one shaft to another
where slippage is not admissible, sprocket chains being used instead of belts
or ropes and sprocket-wheels instead of pulleys. They can be run at high
speed and some forms of chain are so constructed as to be noiseless even at
high speed.
3. DRIVE ARRANGEMENTS:-
Relative position of sprockets in drives should receive careful
consideration. Satisfactory operation can be secured with the centerline of the drive at any
angle to the horizontal, if proper consideration is given. Certain arrangements require less
attention and care than others are, therefore, less apt to cause trouble. Various arrangements
are illustrated in the diagrams. The direction of rotation of the drive sprocket is indicated.
14
4. BEST ARRANGEMENTS:-
Arrangements considered good practice are illustrated in Figs. 1, 2, 3, and 4.
The direction of rotation of the drivesprockets in Figs. 1 and 4 can be reversed.

5. OTHER ACCEPTABLE
ARRANGEMENTS:-
If none of the above arrangements can be followed,
an attempt should be made to use an arrangement as illustrated in Figs. 5, 6, and 7.
15
When the large sprocketis directly above the small sprocket, Fig. 8, a drive
cannot operate with much chain slack. As the chain wears, shaft-center distancemust be

adjusted or an idler be placed against the outsideof the slack strand (near the small sprocket)
to adjustslack and keep the chain in proper contact with the small sprocket. With the drive
slightly inclined, Fig. 5, less care will be required, because the weight of the slack chain strand
helps to maintain better contact between the chain and the sprockets. Wherecenter distances
is short, or drives nearly horizontal, the slack should be in the bottom strand, especially where
take-up adjustmentis limited, Fig. 6 rather than Fig. 9. An accumulation of slack in the top
strand may allow the chain to be pinched between the sprockets, Fig. 9. When small sprockets
are used on horizontal drives, it is better to havethe slack strand on the bottom, Fig. 7, rather
than on the top, Fig. 10. Otherwise, with the appreciable amount of slack, the strands may
strikeeach other.
6. LEAST RECOMMENDED ARRANGEMENTS:-
16

American sprocket manufacturers have adopted 4 specific types of
sprocket
Construction styles as American Standards. In addition to the
standard sprockets,
Special sprockets may be available in the same styles.
Style A -Flat sprocket with no hub extension either side.
Style B -Sprocket with hub extension one side.
Style C -Sprocket with hub extension both sides.
Style D -Sprocket with a detachable bolt on hub attached to
a plate.
7. SPROCKET DIMENSIONALSPECIFICATIONS:-
A.Bottom Diameter (B.D.):

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

F.Maximum Sprocket:
Maximum Sprocket Bore is determined by the required Bore hub wall thickness
for proper strength. Allowance must be made for keyway and setscrews.
G.Face Width:
Face width is limited in its maximum dimension to allow proper clearance to
provide for chain engagement and disengagement. The minimum width is
limited to provide the proper strength to carry the imposed loads.
H.Length thru Bore:
Length Thru Bore (or L.T.B.) mustbe sufficientto allow (LTB) a long enough key to withstand
the torquetransmitted by the shaft. This also assures stability of the sprocketon the shaft.
18
Chapter Number 5
Chain Drives
1. Chain Drives

2. Chain Drive Design
3. Vibrations
4. Avoiding vibration
5. Chain Types
6. Chain Failures
19
CHAIN DRIVES:
 Chain drives are a means of transmitting power like gears, shafts and belt
drives
 Characteristics
High axial stiffness
Low bending stiffness

High efficiency
Relatively cheap
 History and development
First belt drives: China
c100 BC
First chain drives: Roman c200 AD
20

21


Leonardo DaVinci: sketch of leaf type chain c1500 AD –
many similarities to modern chains.
 Galle chains: 19thcentury first mass produced roller
chains (no bushes).
 Hans Renold (Switzerland) 1880–invented modern bush
roller chain
Bush Roller Chains:
Parts of a bush roller chain,

22

Terminology:

 Manufacture:
Bushes and pins: cold drawn, cropped,
Turned/ground, case hardened, ground
Again and shot penned.
Side-plates are stamped from plate.
 Assembly
Pins and bushes are press-fitted into
Appropriate side plates.
2. CHAIN DRIVE DESIGN:-
Chain length and center distance:
Chain must contain even integer number of links
• Hence cannot pick an arbitrary center distance and chain
pitch
• Nearest chain lengths (in pitches) for a contemplated
center distance, CC
, are calculatedby empiricalformulae like (for a two sprocket system:

23
Where N1and N2 is the numbers of teeth on sprockets
and P is the chain pitch.
 The result of which should be ROUNDED UP to the next
even number to calculate the actual center
separation,CA:
Inertial force in chain:
 In addition to the tension required to transmit power,
chain tension also provides centripetal force to move
links around sprockets
 The extra inertial force, Fcf, is given by:
3. Vibrations:

 Chain between sprockets can vibrate like a string
24
Basic equation for natural frequency, fn, of taught
string

Where F is the tension, m is the mass per unit length, L
is the length and k is the mode number

For tight side of chain there are typically ranges of resonant
frequencies given by:
25
Where,
Fcis the tight span tension (excluding inertial contribution)
4. Avoiding vibration:-
To avoid the chain resonating, need to avoid having
sources of excitation with frequencies near possible resonant
frequencies
Obvious source is impact of sprocket teeth on chain

Frequency of these occurs at:
Where ω is the sprocket rotation speed and N is the number
of teeth.
5. Chain Types:-
1) Transmission chains
Chains to transmit rotary power between shafts
Bush roller chains are transmission chains
For more power capacity, multi-strand transmission
chains are used
26

2) Conveyor chain
Rollers sit proud of links and can roll along supporting
surface.
Can be used for transporting materials, as roller scan
support weight.
Can also be used just to support weight of chain if
transmitting power over long distances.
3)Inverted tooth (or silent) chain
Sprocket teeth mesh with shaped links instead of
rollers on chain
Joints between links use rolling rather than sliding
contact
Profile of links are more like in volute gear teeth
Overall effect is to reduce noise

27
4) Leaf (or lifting) chain
Designed for lifting rather (than power transmission)
Do not have to mesh with sprockets, hence no rollers
Therefore can narrower than roller chain with equivalent
strength
Example: fork-lift truck

6.Chain Failures:-
 Failures caused by poor selection
Overload
Failure of side plates due to cyclic load fatigue
Failure of bush or roller due to impact fatigue
 Above failures can still occur due to poor
installation or maintenance
Misalignment
Incorrect or failed lubrication system
28
 If correct chain is selected, installed and
maintained the overall life is determined by wear
 Causes and effects of chain wear
Caused by material removal as chain components slide relative to each
other
Effect of wear is to cause the chain to gradually elongate


As pitch increases, chain sits at larger and large radius on
sprockets
 Limit is when chain jumps over sprocket teeth
 Empirical extension limits are
•2 % for sprockets with less than 200 teeth
•200/N % for sprockets with more than 200 teeth
 Wear life
Typically 15,000 hours for any power, chain or
sprocket size if correctly selected installed and maintained.
29

Chapter Number 6
Wheels and springs
1. Freewheel
2. Flywheel
3. Springs

30
FREEWHEEL:-
A freewheels consists of either a single sprocket or a set of sprockets
mounted on a body which contains an internal ratcheting mechanism
and mounts on a threaded hub.
Mechanics:
The simplest freewheel device consists of two saw-toothed,
spring-loaded discs pressing against each other with the toothed
sides together, somewhat like a ratchet. Rotating in one direction,
the saw teeth of the drive disc lock with the teeth of the driven disc,
making it rotate at the same speed. If the drive disc slows down or
stops rotating, the teeth of the driven disc slip over the drive disc
teeth and continue rotating, producing a characteristic clicking
sound proportionate to the speed difference of the driven gear
relative to that of the (slower) driving gear.
A more sophisticated and rugged design has spring-loaded steel
rollers inside a driven cylinder. Rotating in one direction, the rollers
lock with the cylinder making it rotate in unison. Rotating slower, or
in the other direction, the steel rollers just slip inside the cylinder.

Advantages:
Free wheel mechanism acts as an automatic clutch, making it
possible to change gears in a manual gearbox, either up- or
downshifting, without depressing the clutch pedal, limiting the use
of the manual clutch to starting from standstill or stopping.
Disadvantages:
The major disadvantage of the multiple sprocket freewheel design is that the
drive-side bearing is located inboard of the free wheel, and as sprockets were
added over time, moved the bearing farther from the drive-side axle support. This
resulted in more flexing stress is placed on the axle which can bend or even break.
31
2. FLYWHEEL:-
A flywheel is a rotating mechanical device that is used to store rotational
energy. Flywheels have a significant moment of inertia and thus resist changes in
rotational speed. The amount of energy stored in a flywheel is proportional to the
square of its rotational speed. Energy is transferred to a flywheel by applying
torque to it, thereby increasing its rotational speed, and hence its stored energy.

Conversely, a flywheel releases stored energy by applying torque to a mechanical
load, thereby decreasing its rotational speed.
Energy Stored in a Flywheel:
A flywheel is shown in Fig. when a flywheel absorbs energy its speed
increases and when it gives up energy its speed decreases.
Let m= Mass of the flywheel in kg,
k = Radius of gyration of the fly wheel in meters,
I = Mass moment of inertia of the flywheel about the axis of rotation
in kgm2=m.k2,
N1and N2= Maximum and minimum speeds during the cycle in
r.p.m,
ω1and ω2= Maximum and minimum angular speeds during the cycle
in rad / s,
N= Mean speed during the cycle in r.p.m.

32
The radius of gyration (k) may be taken equal to the mean radius of
the rim (R), because the thickness of rim is very small as compared
to the diameter of rim. Therefore substituting k= R in equation (ii),
we have
Δ E=m.R2.ω2.CS= m.v2.CS (v= ω.R)
From this expression, the mass of the flywheel rim may be
determined.
Notes:
1.In the above expression, only the mass moment of inertia of the
rim is considered and the mass moment of inertia of the hub and
arms is neglected. This is due to the fact that the major portion of

weight of the flywheel is in the rim and a small portion is in the hub
and arms. Also the hub and arms are nearer to the axis of rotation,
therefore the moment of inertia of the hub and arms is very small.
2. The density of cast iron may be taken as 7260 kg / m3and for
cast steel; it may taken as 7800 kg / m3.
3. The mass of the flywheel rim is given by
m= Volume × Density = 2 πR× A× ρ
33
From this expression, we may find the value of the cross-sectional
area of the rim. Assuming the cross-section of the rim to be
rectangular, then
A=b× t
Where b= Width of the rim, and
t = Thickness of the rim.

Knowing the ratio of b/t which is usually taken as 2, we may find the
width and thickness of rim.
3. When the flywheel is to be used as a pulley, then the width of rim should
be taken 20 to 40 mm greater than the width of belt.
3. SPRINGS:-
A spring is defined as an elastic body, whose function is to distort
when loaded and to recover its original shape when the load is
removed. The various important applications of springs are as
follows:
1. To cushion, absorb or control energy due to either shock or
vibration as in car springs, railway buffers, air-craft landing gears,
shock absorbers and vibration dampers.
2. To apply forces, as in brakes, clutches and spring loaded valves.
3. To control motion by maintaining contact between two elements
as in cams and followers.
34
4. To measure forces, as in spring balances and engine indicators.
5. To store energy, as in watches, toys, etc.
Types of springs:
Though there are many types of the springs, yet the following,
according to their shape, are important from the subject point of
view.
Helical springs:

The helical springs are made up of a wire coiled in the
form of a helix and are primarily intended for compressive or tensile
loads. The cross-section of the wire from which the spring is made
may be circular, square or rectangular. The two forms of helical
springs are compression helical spring as shown in Fig.(a) and
tension helical spring as shown in Fig.(b).
Advantages:
(a) These are easy to manufacture.
(b) These are available in wide range.
(c) These are reliable.
(d) These have constant spring rate.
Advantages:
(a) These are easy to manufacture.
(b) These are available in wide range.
(c) These are reliable.
(d) These have constant spring rate.
(e) Their performance can be predicted more accurately.
(f) Their characteristics can be varied by changing dimensions.
35

Conical and volute springs:
The conical and volute springs, as shown in Fig. are used in special
applications where a telescoping spring or a spring with a spring rate that
increases with the load is desired. The conical spring, as shown in Fig.(a), is wound
with a uniform pitch whereas the volute springs, as shown in Fig. (b), are wound in
the form of parabolic with constant pitch and lead angles. The springs may be
made either partially or completely telescoping. This characteristic is sometimes
utilized in vibration problems where springs are used to support a body that has a
varying mass.

36
Torsion springs:
These springs may be of helical or spiral type as shown in Fig. The
helical type may be used only in applications where the load tends to
wind up the spring and are used in various electrical mechanisms.
The spiral type is also used where the load tends to increase the
number of coils and when made of flat strip are used in watches and
clocks.
The major stresses produced in torsion springs are tensile and compressive due to
bending.
Laminated or leaf springs:
The laminated or leaf spring (also known as flat
spring or carriage spring) consists of a number of flat plates (known
as leaves) of varying lengths held together by means of clamps and
bolts, as shown in Fig. These are mostly used in automobiles.
The major stresses produced in leaf springs are tensile and compressive
stresses.

Laminated orleaf springs .Disc or Bellevile springs.
37
Values of allowable shear stress, Modulus of elasticity and Modulus
of rigidity for various spring materials.

38
Standard Size of Spring Wire:
Standard wire gauge (SWG) number and corresponding diameter of
spring wire.

39

Chapter Number 7
Design Parameter`s and Limitations
1. OUTPUT POWER CALCULATIONS
2. DESIGN SPECIFICATIONS
3. SPROCKET WHEEL AND CHAIN
4. SPRINGSSPURGEARS
40

1. OUTPUT POWER CALCULATIONS:-
Let us consider,
The mass of a vehicle moving over the speed breaker=10Kg
(Approximately)
Height of speed brake=10 cm
Work done=Force x Distance
Here,
Force = Weight of the Body
=10Kg x 9.81
=98.1N
Distance traveled by the body = Height of the speed brake
=10 cm
Output power = Work done/Sec
= (89.1x 0.10)/60
=0.1485Watts (For One pushing force)

Power developed for 1vehicle passing over the speed breaker
arrangement for one minute
= 0.1485watts
Power developed for 60 minutes (1 hr) =8.91watts
Power developed for 24hours=213.84watts
41
Velocity Ratio of Chain Drives:
The velocity ratio of a chain drive is given by
𝑉.𝑅.=𝑁1/𝑁2=𝑇2/𝑇1
N1= Speed of rotation of smaller sprocket in r.p.m.,
N2= Speed of rotation of larger sprocket in r.p.m.,
T1= Number of teeth on the smaller sprocket, and
T2= Number of teeth on the larger sprocket.
𝑉.𝑅.=𝑁1/ 𝑁2= 𝑇2/ 𝑇1
𝑉.𝑅. =3619 =1.894
Experimentally,

Revolution
Revolution of shaft by one push:
Using tachometer, 100 rpm =1.666rps
Torque:
Torque produce in on push
𝑇=𝑃×60/2𝜋𝑁
𝑇=0.148×60/2𝜋1.666 = 0.851 𝑁𝑚
42
2. DESIGN SPECIFICATIONS:-
•SHAFT (DIA) = 65 mm
•Diameter of flywheel= 540 mm
•Thickness of flywheel= 20 mm

3. SPROCKET WHEEL AND CHAIN:-
•No of teeth on large sprocket=36
•No of teeth on small sprocket=19
•Dia of large sprocket=460 mm
•Dia of small sprocket= 230 mm
•Length of chain =1620 mm
•Optimum centre distance = 560 mm
4. SPRINGS:-
•Diameter of wire = 2mm
•Mean dia of coil = 12 mm
•Free length of spring = 300mm
5. SPUR GEARS:-
•No of Teeth On Rack = 36
•Rack Length= 230mm
43

•No of Teeth On Pinion =36
•Diameter Of Pinion Gear =270mm
•Thickness of pinion gear=20mm
•Length of speed breaker=290mm
•Width of speed breaker=220mm
•Height of speed breaker=130mm
COST ANALYSIS:-
Cost:
It is defined as the amount of expenditure occurred in bringing out a
product.
Cost is expressed along with the atom viscose of bicycle axle
Rs.15/-per axle cost of bearing Rs.150/.Bearing.
Cost of Elements:
The different cost is placed in three categories.
Material Cost
Labor Cost
Other Expenses
Material Cost:

It is the cost on the material, which is converted into product. This is
of two types:
Direct Material Cost
It is cost of all those materials which when worked upon become the
integral part of the product. For example lathe bed casting when
machined, heat treated and grounded becomes a lathe bed.
44
Indirect Material Cost
All those materials, which are consumed during manufacturing for
processing a product, but do not become part of product. For
example electric energy, cutting oil, grease, water and cotton waste.
Prime Cost
This is also known as direct cost. Prime Cost = direct material cost +
direct labor cost and expenses
Factory Cost
This is also known as factory cost. Factory cost = prime cost + factory expenses.

Office Cost
This is also known as production office cost = factory cost +
administrative expenses + all and the expenses.
Total Office
This is also known as selling cost. Total cost = office cost + selling
and distribution expenses
Selling price of product
Selling cost = total cost + profit loss
Brake Even Chart:
This is graphical illustration to show loss and profit region. This type
is deciding the no of units to be made at which three is neither any
loss nor any profit. It is arrived it a following
45
Fixed Cost:
This is the cost, independent of product. This cost is three even if
the product is nil.

Labor cost
It is the labor which converts raw material into product which tools
and machines and hence the cost over the labor
Direct Labor cost
All the labors are working on the machines and material who can be
identified with the product, are called direct labor and hence cost
over them. For example, a lathe operator, a milling man.
Indirect labor cost
All the labors that help in manufacturing cycle but cannot be
identified directly with a particular product and hence cost over
them. For example, Sweepers, gate keepers, rigors, store keepers
etc.
Other Expenses
All those expenses not covered under labor and material cost fall under this
category. They are also of two types.
Direct expenses
All those expense, which can be assigned to a particular job, are
placed in this category. This will include the following.

Expenses incurred in preparing design, drawing and process sheet.
Cost of jobs, fixtures is any made / hired for the job.
Patterns used for the mold.
Any consultation fee paid for the job.
46
Indirect expenses
All other expenses left out for above. They make a major part of the
cost. These expenses are of following type.
Factory Expenses
This is also known as “factory over heads”, factory on cost on work
on cost.
Administrative expenses
This is also known as office on cost.
Selling expenses
Distribution expenses
R & D expenses
Selling price of product, it can be calculated as follows:

Selling price of pipe bending machine:
Prime Cost:
Prime cost = material cost + labor cost + other cost.
=Rs,4500/.
Bearing, cutting tool, screw etc. = Rs500/.
Material cost = Rs3500.
Labor cost = 15hrs (no of machine operators * Rs50 per hour)
= 15 hour (5* Rs50 per hour)
= 500Rs.
47
Other expenses:
= manufacturing process (painting + machines and energy consumed)
Other expenses = 500 + 15hours 10Rs/hour
= 650/.
Factory Cost:

Factory cost = prime cost + factory expenses
= 4500 + 500 = Rs5000.
Total cost:
Total cost = office cost + selling cost and distribution cost =Rs 10150.
Selling cost:
Selling cost = total cost + profit lose.
= 10150 + (10 % * total cost)
= 10150 + (10 * 10150/100)= Rs.11155
By adding the general sales taxes = selling cost + 16% = 11155+ 16%
= Rs. 12939
Selling Cost = Rs. 12939
48

REFERENCES:-
I .Department of Mechanical Engineering Queen’s Building, University
of Bristol, Bristol, BS8 1TR, UK
II. A Textbook of Design of Machine elements “2” by R.S.KHURMI
AND J.K.GUPTA.
III. Automobile Engineering, KirpalSingh.
IV. Automobile Engineering, S.M.Pandey& K.K. Shah.
VI. Shigley Tata McGraw hills (Machine Design).
VII. Generation of Electricity through Speed Breaker Mechanism.
VIII.EVERY SPEED BREAKER IS NOW A SOURCE OF POWER.

Project was done by Pillaka ganesh BATCH
GANESH.P = (14597-M-047)
PRASAD.M = (14597-M-031)
ADITYA NARAYANA.G = (14597-M-019)
SATISH.P = (14597-M-037)
SAI.J = (14597-M-020)
THE END

Generation of electricity through speed breaker mechanism(AVANTHI CLG MAKAVARPALLEM)

Generation of electricity through speed breaker mechanism(AVANTHI CLG MAKAVARPALLEM)

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