MAHARASHTRA ACADEMY OF NAVAL EDUCATION & TRAINING,

(PUNE) BACHELOR OF TECHNOLOGY IN MARINE ENGINEERING

TECHNICAL PAPER PRESENTATION

YASHWANTRAO CHAVAN MAHARASHTRA OPEN UNIVERSITY(2015-2016)

GUIDED BY : Prof. V.G.Mehendale

Batch - XIDivision - IIIGroup - A

GROUP MEMBERS

GROUP MEMBERSSubmitted By:1. Raza Ishtiaq. (Group Leader) (11106)2. Nikhil Nishant. (11089)3. Nikhil Mayank. (11088)4. Piyush Kumar. (11095)5. Pradeep Kumar. (11096)6. Pratit Rajak. (11099)7. Rishav Kumar. (11107)8. Rohit Kumar. (11109)9. Devendra Bansal. (11023)10.Devendra Chaurasia. (11027)

________________ _________________ ________________

Prof. V.G.Mehendale Prof . Q. Tayabji Prof . S. Devgaonkar ( Project Guide ) ( Head Of Ship - In- Campus ) ( Principal )

CERTIFICATE:This is to certify that the project entitled: “ELECTRICITY GENERATION FROM SPEED BREAKER”Sr. No.

Name of Cadet

PRN No.

Sr. No.

Name of Cadet PRN No.

01 Raza Ishtiaq VV2300047

06 Pratit Rajak VV2300127

02 Nikhil Nishant VV2300113

07 Rishav Kumar VV2300080

03 Nikhil Mayank VV2300101

08 Rohit Kumar VV2300081

04 Piyush Kumar VV2300077

09 Devendra Bansal VV2300013

05 Pradeep Kumar VV2300078

10 Devendra Chaurasia VV2300018In partial fulfillment for the requirements of Bachelor of Technology ( Marine Engineering ) ____________ ____________ Prof. V.G.Mehendale (Internal Examiner (External Examiner)

ACKNOWLEDGEMENT

This project work is made explaining about the installation of a Electricity Generating Speed Breaker in our campus. Many people have made their best contribution to make this project a success. We wish to thank a number of people who have taken efforts and helped us in the best way possible in our project and made it successful.We would like to thank professors for guiding us through the project. Our sincere thanks goes to Professor Qaiser Tayabji (head of ship in campus), Prof. R.K. Vaidya and Prof. S. V. Joshi who have helped us immensely throughout our project.Our project is a success because of the guidance and a pathway shown by our project guide Professor V.G. Mehendale, so a quote of thank will be incomplete without thanking him.And finally we would like to thank our ship in campus college staff and personnel as well as our workshop staff, for their grateful help and support in helping to realize this project.

TABLE OF CONTENTSSr.No. Topic Page No.

01 INTRODUCTION 08-1202 ESTIMATED OBJECTIVE 13-1403 MATERIALS REQUIRED 15-1604 SYSTEM OVERVIEW & DESIGN 17-2205 MODULE DESIGN 23-5106 TESTING & TROUBLESHOOTING 52-5307 CONCLUSION 54-5508 BOOKS REFERRED 56

INTRODUCTION

INTRODUCTIONThe current situation of power shortage in the

world is nothing but grim. So, this is our small step to try to improve this

situation by our project.In India alone ,there are more than 60 million

vehicles on the roads everyday.The project makes use of pressure energy of the

vehicle passing over the speed breaker and converts it into electrical energy with the help of various gears and spring systems .

Making use of the mechanism we can install it on

highways primarily at Toll-Gates and other various places.

Other places where the project can be used includes parking lots, malls etc. Alternately this can also be used as a security system for vehicle parking , where the alarm can be connected to the output so that when the vehicle passes over the speed breaker , an alarm circuit can be triggered.

• Onboard Application: It can be fitted onto the entry gate of a Roll-On & Roll-Off ship where on an average, around 2000 vehicles enter & exit & each vehicle having at least two wheels, therefore on an average the speed breaker can be pressed around 4000 times at a given loading/unloading time. The energy so produced, can be stored in a large capacity battery and can be used to operate the Gate of the Ro-Ro ship, or some local lighting provision can be made available.

OBJECTIVES• To develop clean & green source of electricity.

• To tap the potentially useful potential energy from vehicles plying on the roads.

• To make an alternative for developing a unique & cheap method of producing energy.

ESTIMATED OBJECTIVES

Estimated Objective

On completion of the project• We will be able to generate enough power that can light

up a L.E.D. lamp when a single vehicle passes over the speed breaker.

• This energy may alternately be tapped and stored in a battery or a capacitor-bank , which can then be used whenever required.

• Specific options on power usage include using in Vehicle-counters entering the campus , In Rooms illuminated by L.E.D.s or in RFID Sensors on vehicles.

MATERIALS REQUIRED

Materials RequiredSerial No.

Part Type Quantity

Estimated Cost

1 Springs Helical 02 -2 Gears Rack &

Pinion01+01 580+1040

3 Gears 03 1470+3864 Bearings Ball 08 5675 Motor Synchronou

s01 3937.5

6 Nut 16X75 04 1057 Nut Bolts &

Washer5X16 16 192

8 Paint & Brush

- 02+01 230

TOTAL 8507.5/- INR

System OVERVIEW & dESIGN

• The system makes use of the general speed breaker arrangement with the modification that the speed breaker itself travels in a vertical axis & having a Spring under it to push it back to its original position.

TOP PLATE

SPRING

BEARING CARRIER

SYNCHRONOUS MOTORBEARING GUIDE

RACK

PLATE

BOTTOM PLATE

• When the TOP PLATE goes down due to the weight of the vehicle,the RACK that is welded to the TOP PLATE travels in a vertical direction downwards and rotates the gears that are meshed with it & hence giving the rotation to the gear mounted on the motor,thereby rotating the rotor of the motor & generating electric power.

TOP VIEW

GEAR 1PLATEMOTOR

RACK GUIDE

PLATE FOR SUPPORTING MOTOR

SIDE VIEW

INCLINED RAMPHORIZONTAL RAMP

SPEED BREAKER

MODULE dESIGN

We have used two number of plates for forming the top and base of our speed breaker

BOTTOM PLATE

TOP PLATE

The plates are made up of MILD STEEL. The dimensions of which are given as follows:

TOP PLATE : 80*46 cms THICKNESS : 1cm

BOTTOM PLATE : 100*50 cms THICKNESS : 1cm

After we furnished the whole setup, we decided that the travel of the top plate would be 8 cm. Due to this we stumbled upon the problem of bumping of the vehicle onto the ramp when it passes over the speed breaker, due to which, the vehicle may disbalance. The representation of which is as given below.

The vehicle may bump dangerously at this point

Therefore we devised a solution for it. With the help of flexible plate of MILD STEEL, we can successfully negate the above problem of bumping. The plate will be placed under the exposed surface of speed breaker i.e. under the rubber mat that we are using in our case. The flexible plate will extend onto both the ramps where it will be bolted for fixing them and also there will be slots cut around the hole for the bolt so that there will be a slight movement for the plate when it deforms under the load of the vehicle.

We have used two number of Helical Springs which are placed in between the top and base plate. These spring will actually bear the load of the vehicle and will compress when the vehicle will pass over the top plate & then return to its original position when the vehicle passes.

The Dimensions of the spring are as follows:• MATERIAL OF SPRING: Spring Steel• FREE LENGTH: 37.5cm• OUTER DIAMETER: 10cm• THICKNESS OF EACH COIL (d):

10mm• NUMBER OF ACTIVE COILS: 6

RACK CALCULATIONS:

Assumptions: Module = 2mmNumber of Teeth = Compression length / (module*3.14) = 80/(2*3.14) =12.74 or 13 Length of rack = Number of teeth * module * 3.14 = (13*2*3.14) = 82mm =82+20+20=122mmWidth of rack = 20 mm GEAR CALCULATIONS: (Trial & Error Method)For 1st Pinion m ≥ 1.26

Where:m= ModuleT= Torque on tooth (F.O.S. =1.3)Y=Form Factor=0.36σ= Design Bending Stress=120 N/Ψ=Face Width / Module =10Z=Number of teeth=16 (Assumed)

So, torque on tooth= 120 9.81 16 Nmm =18835.2 Nmm It is assumed that the load is of 120 Kg on the rack.

Now, m= 1.26 =1.92Hence it is safe to operate at m < 2.So,Number of teeth= 16Module (m)=2Face Width()=20mmP.C.D. =32mm Now,Formula Used= Speed of driver () = Number of teeth on driven() Speed of driven () Number of teeth on driver ()

1st Reduction of Speed:So,RPM= 1164.6 16 = 310.56 R.P.M. 60 (Assumed)Then, 1st gear Specifications:Number of teeth= 60 (Assumed)Module (m)=2Face Width()=20mmP.C.D.=120mmAlso , m= 1.26 =1.24It is safe to operate as m<2

For 2nd Pinion m= 1.26 =1.68It is safe to operate as m<2 So, Number of teeth=12 (Assumed)

Module (m)=2Face Width()=20mmP.C.D.=120mm

For 2nd Reduction of speedSo,RPM= 310.56 12 = 53.27 R.P.M. 70(Assumed)Then, 2nd gear Specifications:Number of teeth= 70 (Assumed)Module (m)=2Face Width()=20mmP.C.D.=140mmAlso , m= 1.26 =1.17It is safe to operate as m<2.

Spring Guides: Material Used: Mild Steel (M.S.)

Top Spring Guide : • Length = 25cm• Outer Diameter = 60mm• Thickness = 0.5cm

Bottom Spring Guide :• Length = 29.5cm• Outer Diameter =68mm TOP SPRING GUIDE BOTTOM SPRING

GUIDE • Thickness =0.5cm

We have designed 3 number of shafts for mounting gears in our project. These shafts were then suitably machined for making keyways so that the gear can be locked onto the shaft with proper keys that fit in the keyway of the shaft & gear. The dimensions of the shaft are given below:

Shaft 1 :

Length : 50mmDiameter : 12mm

Shaft 2 :Composite ShaftSection 1: Length : 50mm Diameter : 16mmSection 2: Length : 50mm Diameter : 12mm

Shaft 3 :

Length : 50mmDiameter : 16mm

SCALE 1:1

SCALE 1:1

SCALE 1:1

Deep groove (Conrad) bearing

Primarily designed to support radial loads, the thrust capacity is about 70% of radial load capacity.

Load capacity is limited by the number of balls.

Ball Bearings

Bearings• Rolling Contact Bearings – load is transferred

through rolling elements such as balls, straight and tapered cylinders and spherical rollers.

• Journal (sleeve) Bearings – load is transferred through a thin film of lubricant (oil).

BearingsRolling Contact Bearings-Load is

transferred through elements in rolling contact rather than sliding contact.

Design Considerations

Bearing life and reliability Bearing speed (rpm) Space limitation Accuracy

• Bearing load – radial, thrust (axial) or both.

Radial loadRadial load

Thrust load

Bearings are selected from catalogs, before referring to catalogs you should know the following:

Single -Row Deep Groove Ball Bearing

Typical ball bearing. Handles light axial loads as well as radial loads .

We have used 4 in number of bearings in our project. The bearings are fixed in a square pipe. Each bearing is bolted onto a single pipe, the dimensions of which are as given below:

• Length of each pipe = 19.5cm• Width = 3.5cm (of each side of square)

The Dimensions of the Bearings are as follows:• Outer Diameter = 40cm• Bore = 16cm

Also we have used guides for bearings,the dimensions of which are as follows:• Length = 26cm• Width = 5cm• Inner Width = 4.5cm• Thickness = 0.025cm

INVERTED VIEW OF SQUARE PIPE WITH BEARING BOLTED

We have used a Synchronous Motor to generate electric power. The Specifications of which are as follows:

SINGLE-PHASE SYNCHRONOUS MOTOR (REVERSIBLE)R.P.M. = 60Voltage = 240 VoltsFrequency = 50 HzTorque = 26 Kgcm

TESTING & TROUBLESHOOTING

PROBLEMS AND SOLUTIONS:• SELECTING SUITABLE MOTOR• SELECTION OF SPRINGS• ACHIEVING PROPER BALANCE OF SPRING AND TORQUE• PRESS FITTING OF BEARINGS INTO THE PLATEPROBLEM 1: LOAD TESTING OF SPRINGS-one of the basic principle of the spring is to withstand a force while having the ability to compress or extend and then to return to its original position.SOLUTION: We carried out the load testing of different springs ,to see whether the springs can withstand the load of the vehicle.It was carried out in a very simple manner(trial and error) -the springs were aligned between two plates , different weights were applied on the springs and the compression were noted down the weights varied from 60 kgs to 180 kgs and was tabulated and compared with our decided travel, after testing 2 springs we came up with the springs that was suitable for the load variation between 60 -200 kgs.

PROBLEM 2: When we assembled the gears and coupled the motor to the gears, we noticed that the torque produced was not enough to drive the motor to the extent at which it generated electricity.SOLUTION: When we removed all but one gear and meshed the gear that drove the motor, with the rack we could get the desired output instantly.

PROBLEM 3: When we were press fitting the bearing onto the plate, due to mechanical error, the diameter of the hole in the plate was made more than that of the outer diameter of the bearing, making it loose.SOULTION: We welded along the internal diameter of the hole in the plate & the again machined the hole carefully on the lathe machine.

CONCLUSION

The existing source of energy such as coal ,oil etc. may not be adequate to meet the ever increasing energy demands. these conventional sources of energy are also depleting and may be exhausted.This project is one step to path of exploring the possibilities of energy from several non-conventional energy sources, this is a type of vibration harvesting .This uses waste energy of vehicles and converts kinetic energy to electrical energy.future work can consist of re-designing of this model to see exactly how much data we may be missing with the project we came up with low price, weight and capacity.

Thank you