GENERATION OF ELECTRICITY THROUGH SPEED BREAKER

Generation of Electricity through Speed Breaker Mechanism

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GENERATION OF ELECTRICITY THROUGH SPEED BREAKER

MECHANISM

Department Of Mechanical Engineering

RACHNA COLLEGE OF ENGINEERING AND TECHNOLOGY, GUJRANWALA

(A Constituent College of UET Lahore.)

SESSION 2010

Submitted By

Samiullah Kakar (2010-ME-442)

Project Supervisor

Engr. Muhammad Qasim Tatla

Assistant Professor, Department of Mechanical Engineering

RACHNA COLLEGE OF ENGINEERING AND TECHNOLOGY, GUJRANWALA.


As partial fulfillment of the requirements for the

Bachelor’s Degree

In

MECHANICAL ENGINEERING

This report is submitted to

Department of Mechanical Engineering,

Rachna College of Engineering and Technology, Gujranwala

This is declaring that work submitted in this report is my own, and any work that is not mine has

been quoted and acknowledged in the references.

Approved On------------------------------

Internal Examiner: Engr. Muhammad Qasim Tatla

Signature: -----------------------------------------

External Examiner:

Signature: -------------------------------------------

Department of Mechanical Engineering,

Rachna College of Engineering and Technology, Gujranwala

(A Constituent College of UET, Lahore)


Dedication

I dedicate this work to my beloved parents for always supporting

me, because they are the driving force in my life and career.

Without their love, none of this would matter. Throughout my life,

they have actively supported me in my determination to find and

realize my potential, and to make this contribution to our world.


Acknowledgements

Thanks to ALLAH ALMIGHTY that enabled me to work in this project because without His approval

man can do nothing. After almighty Allah to his prophet, HAZRAT MUHAMMAD (PBUH), the most

perfect an exalted forever source of guidance and knowledge humanity as a whole.

There are a number of people without whom this project might not have been written, and to whom I am

greatly indebted.

I will forever be thankful to my advisors, Engr. Muhammad Qasim Tatla for supporting me during this

study. He has provided insightful discussions about the research. His support and penetrates has allowed

me to complete one of my many life goals. I would also thankful to our Honorable teacher Engr.

Nouman Javed for guiding me on all my work and project. I value the guidance that was giving to me.

Regards

Samiullah Kakar


Contents ABSTRACT ........................................................................................................................................ 1

chapter number 1

INTRODUCTION OF THE PROJECT .............................................................................................. 3

1. INTRODUCTION ..................................................................................................................... 4

2. SCOPE OF THE PROJECT ...................................................................................................... 4

chapter number 2

DEMONSTRATION OF THE PROJECT .......................................................................................... 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 DIMENSIONAL SPECIFICATIONS ................................................................. 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


1

ABSTRACT

Man in his lifetime, uses energy in one form or the other. In fact whatever happens in

nature, results, out of the conversion of energy in one form or the other. The blowing of the

wind, the formation of the clouds and the flow of water are a few examples that stand

testimony to this fact. The extensive usage of energy has resulted in an energy crisis, and

there is a need to develop methods of optimal utilization, which will not only ease the crisis

but also preserve the environment. Energy conservation is the cheapest new source of

energy. This project attempts to show how energy can be tapped and used at a commonly

used system, the generation of electricity through the speed breaker mechanism.

Generation of electricity through the speed breaker mechanism is one of the most recent

power generation concepts. This device converts the kinetic energy of the vehicles

into electric energy by installing movable speed breaker on the road, it takes the stroke

motion of the vehicles and converts it to the rotary motion by rack and pinion mechanism

and it generates the electricity. This project also explains clearly, the working principle of

the designed system, its practical implementation, and its advantages. Design of each

component has been carried out using standard procedures, and the components have

been fabricated and assembled. A similar model of the system has been modeled using

AutoCAD 2007. Practical testing of the system has been done with different loads at

different speeds. The utilization of energy is an indication of the growth of a nation. One

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

consume more and more energy. And this project is best source of energy that we get in

day to day life.


2

GENERATION OF ELECTRICITY THROUGH SPEED BREAKER

MECHANISM


3

Introduction of the project

1. INTRODUCTION

2. SCOPE OF THE PROJECT

Chapter Number 1


4

1. INTRODUCTION:- This project attempts to show how energy can be tapped and used at a commonly

used system- the road speed-breakers. The number of vehicles passing over the speed

breaker in roads is increasing day by day. A large amount of energy is wasted at the

speed breakers through the dissipation of heat and also through friction, every time a

vehicle passes over it. There is great possibility of tapping this energy and generating

power by making the speed-breaker as a power generation unit. The generated power

can be used for the lamps, near the 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.

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. The average demand is 17,000MW and the shortfall

is between 4,000 and 5,000MW. One might conclude that to be materially rich and

prosperous, a human being needs to consume more and more energy.

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

country is lot affected by this energy crisis in the world .The major issue is electric crisis

which is known as load shedding Pakistan’s small manufacturing markets are lot affected

by the rise of energy prices.

By just placing a unit like the “Power Generation Unit from Speed Breakers”, so much of

energy can be tapped. This energy can be used for the lights on the either sides of the

Roads and thus much power that is consumed by these lights can be utilized to send power

to these villages.

http://en.wikipedia.org/wiki/Pakistan


5

Chapter Number 2

Demonstration of the Project

1. WORKING PRINCIPLE

2. BLOCK DIAGRAM


6

1 WORKING PRINCIPLE:- The project is concerned with generation of electricity from speed breakers-like set

up. The load acted upon the speed breaker - setup is there by transmitted to rack and

pinion arrangements.

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

using the rack and pinion arrangement. The axis of the pinion is coupled with the sprocket

arrangement. The sprocket arrangement is made of two sprockets. One of larger size and

the other of smaller size (free wheel). Both the sprockets are connected by means of a

chain which serves in transmitting power from the larger sprocket to the smaller sprocket.

As the power is transmitted from the larger sprocket to the smaller sprocket, the speed

that is available at the larger sprocket is relatively multiplied at the rotation of the smaller

sprocket. The axis of the smaller sprocket is coupled to a fly wheel. The fly wheel is

coupled to the shaft at axis of the smaller sprocket. Hence the speed that has been

multiplied at the smaller sprocket wheel is passed on to this fly wheel of larger dimension.

The smaller sprocket is coupled to the larger fly wheel. So as the larger fly wheel rotates

at the multiplied speed of the smaller sprocket, the smaller sprocket following the larger

sprocket still multiplies the speed to more intensity. Hence, although the speed due to the

rotary motion achieved at the larger sprocket wheel is less, as the power is transmitted to

fly wheel, finally the speed is multiplied to a higher speed. This speed which is sufficient to

rotate a shaft connected to generator. The rotor (shaft) rotates the generator. The

generator produces the DC current. This DC current is now sent to the storage battery

where it is stored during the day time. This current is then utilized in the night time for

lighting purposes on the either sides of the road to a considerable distance.


7

2 BLOCK DIAGRAM:-

SPEED BRAKER

ARRANGE

MENT

BATTERY INVERTER

STREET

LIGHTS

GENERATOR

RACK & PINION

AND CHAIN

SPROCKET ARRANGEMENT

Fly wheel


8

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


9

1. FABRICATION DETAILS:- The frame structure for the total unit is fabricated using L-Angle frames and

ordinary frames. These frames are made of mild steel. They are held to proper dimensions

are attached to form a unit with the help of welding. Then the bearings which are of

standard make are kept in place with their respective shafts through them and are welded

to the frame structure. The shafts are also made of mild steel. Hinges are used to move the

speed breaker arrangement by welding it to the frame structure. These hinges are

responsible for the movement of the speed breaker in an up and down motion. A rack

which are made up of mild steel is welded to the speed breaker arrangement. A pinion

which is also made up of mild steel and which has Thirty six teeth is fitted on the shaft

initially, and welded. This pinion tooth is exactly made to mate with the teeth of the rack.

A bicycle sprocket and chain arrangement of standard make is fitted with the larger

sprocket on the top shaft and its smaller sprocket on the bottom shaft. The sprocket wheels

are welded to the shafts. A fly wheel that is made of cast iron is machined suitably to the

precise dimensions in a lathe and is placed on the shaft with its axis coinciding with the

axis of the shaft and is welded. A special stand arrangement is made to seat the 12v DC

generator using frames. A 12v DC generator is placed within the seat and is held firm

using bolts and nuts.

2. FABRICATION MODEL SHOWING INNER PARTS:- Wires are connected to the terminals of the DC generator and its other ends are

connected to a Lead-Acid battery. Another wire is taken from these points on the battery

and its other ends are connected to the positive and negative terminal of an inverter. An

output wire from the inverter is sent to the light.


10

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


11

5. 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.


12

Chapter Number 4

Rack, Pinion and Sprocket

1. RACK AND PINION

2. SPROCKET

3. DRIVE ARRANGEMENTS

4. BEST ARRANGEMENTS

5. OTHER ACCEPTABLE ARRANGEMENTS

6. LEAST RECOMMENDED ARRANGEMENTS

7. SPROCKET DIMENSIONAL

SPECIFICATIONS


13

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.


14

2. SPROCKET:- A sprocket or sprocket-wheel is a profiled wheel with teeth or cogs that mesh with

a chain, track or other perforated or indented material. The name "sprocket" applies

generally to any wheel upon which are radial projections that engage a chain passing

over it. It is distinguished from a gear in that sprockets are never meshed together directly,

and differs from a pulley in that sprockets have teeth and pulleys are smooth. The word

"sprockets" may also be used to refer to the teeth on the wheel.

Sprockets are used in bicycles, motorcycles, cars, tracked vehicles, chainsaws and

other machinery either to transmit rotary motion between two shafts where gears are

unsuitable or to impart linear motion to a track, tape etc. Perhaps the most common form

of sprocket may be found in the bicycle, in which the pedal shaft carries a large sprocket-

wheel, which drives a chain, which, in turn, drives a small sprocket on the axle of the rear

wheel. Early automobiles were also largely driven by sprocket and chain mechanism, a

practice largely copied from bicycles.

Sprockets are of various designs, a maximum of efficiency being claimed for each by its

originator. Sprockets typically do not have a flange. Some sprockets used with timing

belts have flanges to keep the timing belt centered. Sprockets and chains are also used

for power transmission from one shaft to another where slippage is not admissible,

sprocket chains being used instead of belts or ropes and sprocket-wheels instead of

pulleys. They can be run at high speed and some forms of chain are so constructed as to

be noiseless even at high speed.

3. DRIVE ARRANGEMENTS:-

Relative position of sprockets in drives should receive careful consideration. Satisfactory

operation can be secured with the centerline of the drive at any angle to the horizontal, if

proper consideration is given. Certain arrangements require less attention and care than

others are, therefore, less apt to cause trouble. Various arrangements are illustrated in the

diagrams. The direction of rotation of the drive sprocket is indicated.

http://en.wikipedia.org/wiki/Wheel

http://en.wikipedia.org/wiki/Roller_chain

http://en.wikipedia.org/wiki/Caterpillar_track

http://en.wikipedia.org/wiki/Gear

http://en.wikipedia.org/wiki/Pulley

http://en.wikipedia.org/wiki/Bicycle

http://en.wikipedia.org/wiki/Motorcycle

http://en.wikipedia.org/wiki/Automobile

http://en.wikipedia.org/wiki/Continuous_track

http://en.wikipedia.org/wiki/Chainsaw

http://en.wikipedia.org/wiki/Machine

http://en.wikipedia.org/wiki/Flange

http://en.wikipedia.org/wiki/Toothed_belt

http://en.wikipedia.org/wiki/Toothed_belt


15

4. BEST ARRANGEMENTS:- Arrangements considered good practice are illustrated in Figs. 1, 2, 3, and 4. The

direction of rotation of the drive sprockets in Figs. 1 and 4 can be reversed.

5. OTHER ACCEPTABLE ARRANGEMENTS:- If none of the above arrangements can be followed, an attempt should be made to use an

arrangement as illustrated in Figs. 5, 6, and 7.


16

When the large sprocket is directly above the small sprocket, Fig. 8, a drive cannot

operate with much chain slack. As the chain wears, shaft-center distance must be adjusted

or an idler be placed against the outside of the slack strand (near the small sprocket) to

adjust slack and keep the chain in proper contact with the small sprocket. With the drive

slightly inclined, Fig. 5, less care will be required, because the weight of the slack chain

strand helps to maintain better contact between the chain and the sprockets. Where center

distances is short, or drives nearly horizontal, the slack should be in the bottom strand,

especially where take-up adjustment is limited, Fig. 6 rather than Fig. 9. An accumulation

of slack in the top strand may allow the chain to be pinched between the sprockets, Fig. 9.

When small sprockets are used on horizontal drives, it is better to have the slack strand on

the bottom, Fig. 7, rather than on the top, Fig. 10. Otherwise, with the appreciable amount

of slack, the strands may strike each other.

6. LEAST RECOMMENDED ARRANGEMENTS:-


17

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 DIMENSIONAL SPECIFICATIONS:- 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 sprocket with odd number of teeth cannot be

measured directly, caliper diameters are the measurement across the tooth spaces nearly

opposite.


18

c. Pitch Diameter (P.D.):

The diameter across to the pitch circle which is the circle Followed by the centers of

the chain pins as the sprocket revolves in mesh with the chain.

PD =PITCH

SIN (180/Nt)

d. Outside Diameter (O.D.):

The measurement from the tip of the sprocket tooth across to the corresponding

point directly across the sprocket. It is comparatively unimportant as the tooth length is not

vital to proper meshing with the chain. The outside diameter may vary depending on type

of cutter used.

OD = (Pitch) (.6 + COT [180 / Nt])

e. Hub Diameter (HOD):

That distance across the hub from one side to another. This diameter must not

exceed the calculated diameter of the inside of the chain side bars.

f. Maximum Sprocket:

Maximum Sprocket Bore is determined by the required Bore hub wall thickness for

proper strength. Allowance must be made for keyway and setscrews.

g. Face Width:

Face width is limited in its maximum dimension to allow proper clearance to provide

for chain engagement and disengagement. The minimum width is limited to provide the

proper strength to carry the imposed loads.

h. Length thru Bore:

Length Thru Bore (or L.T.B.) must be sufficient to allow (LTB) a long enough key to

withstand the torque transmitted by the shaft. This also assures stability of the sprocket on

the shaft.


19

Chapter Number 5

Chain Drives

1. Chain Drives

2. Chain Drive Design

3. Vibrations

4. Avoiding vibration

5. Chain Types

6. Chain Failures


20

1. 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


21

Leonardo DaVinci: sketch of leaf type chain c1500 AD – many similarities to

modern chains.

Galle chains: 19th century 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

peened.

Side-plates are stamped from

plate.

Assembly

Pins and bushes are press-fitted into appropriate side plates.

2. CHAIN DRIVE DESIGN:- Chain length and center distance:

Chain must contain even integer number of links

• Hence cannot pick an arbitrary center distance and chain pitch

• Nearest chain lengths (in pitches) for a contemplated center distance, CC

, are calculated by empirical formulae like (for a two sprocket system:

Where N1and N2 is the numbers of teeth on sprockets and P is the chain pitch.

The result of which should be ROUNDED UP to the next even number to calculate the

actual center separation, CA:


23

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

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


24

For tight side of chain there are typically ranges of resonant frequencies given by:

Where,

Fc is 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


25

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 involute gear teeth Overall effect is to

reduce noise


26

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

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


27

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.


28

Chapter Number 6

Wheels and springs

1. Freewheel

2. Flywheel

3. Springs


29

1. FREEWHEEL:- A freewheels consists of either a single sprocket or a set of sprockets mounted on a body

which contains an internal ratcheting mechanism and mounts on a threaded hub.

Mechanics:

The simplest freewheel device consists of two saw-toothed, 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.

http://en.wikipedia.org/wiki/Freewheel

http://en.wikipedia.org/wiki/Ratchet_(device)

http://en.wikipedia.org/wiki/Spring_(device)

http://en.wikipedia.org/wiki/Ratchet_(device)

http://en.wikipedia.org/wiki/Roller_(disambiguation)

http://en.wikipedia.org/wiki/Clutch

http://en.wikipedia.org/wiki/Gearbox


30

2. FLYWHEEL:- A flywheel is a rotating

mechanical device that is used to

store rotational energy. Flywheels

have a significant moment of

inertia and thus resist changes in

rotational speed. The amount of

energy stored in a flywheel is

proportional to the square of

its rotational speed. Energy is

transferred to a flywheel by

applying torque to it, thereby

increasing its rotational speed, and

hence its stored energy.

Conversely, a flywheel releases

stored energy by applying torque to a mechanical load, thereby decreasing its rotational

speed.

Energy Stored in a Flywheel:

A flywheel is shown in Fig. when a flywheel absorbs energy its speed increases and when

it gives up energy its speed decreases.

Let m= Mass of the flywheel in kg,

k = Radius of gyration of the flywheel in meters,

I = Mass moment of inertia of the flywheel about the axis of rotation in 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.

http://en.wikipedia.org/wiki/Rotational_energy

http://en.wikipedia.org/wiki/Moment_of_inertia

http://en.wikipedia.org/wiki/Moment_of_inertia

http://en.wikipedia.org/wiki/Rotational_speed

http://en.wikipedia.org/wiki/Torque


31

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 / m3 and 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


32

From this expression, we may find the value

of the cross-sectional area of the rim.

Assuming the cross-section of the rim to be

rectangular, then

A=b× t

where b= Width of the rim, and

t = Thickness of the rim.

Knowing the ratio of b/twhich is usually

taken as 2, we may find the width and

thickness of rim.

4. When the flywheel is to be used as a

pulley, then the width of rim should be taken

20 to 40 mm greater than the width of belt.

3. SPRINGS:- A spring is defined as an elastic body, whose function is to distort when loaded and

to recover its original shape when the load is removed. The various important applications

of springs are as follows :

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 springloaded valves.

3. To control motion by maintaining contact between two elements as in cams and

followers.

4. To measure forces, as in spring balances and engine indicators.

5. To store energy, as in watches, toys, etc.


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Types of Springs:

Though there are many types of the springs, yet the following, according to their

shape, are important from the subject point of view.

Helical springs:

The helical springs are made up of a wire coiled in the form of a helix and is

primarily intended for compressive or tensile loads. The 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 springas 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.

(e) Their performance can be predicted more accurately.

(f) Their characteristics can be varied by changing dimensions.


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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.


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Torsion springs:

These springs may be of helical or spiral type as shown in Fig. The helical type may

be used only in applications where the load tends to wind up the spring and are used in

various electrical mechanisms. The spiral type is also used where the load tends to increase

the number of coils and when made of flat strip are used in watches and clocks.

The major stresses produced in torsion springs are tensile and compressive due to

bending.

Laminated or leaf springs:

The laminated or leaf spring (also known as flat spring or carriage spring) consists

of a number of flat plates (known as leaves) of varying lengths held together by means of

clamps and bolts, as shown in Fig. These are mostly used in automobiles.

The major stresses produced in leaf springs are tensile and compressive stresses.

Laminated or leaf springs. Disc or Bellevile springs.


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Values of allowable shear stress, Modulus of elasticity and Modulus of rigidity for various

spring materials.


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Standard Size of Spring Wire:

Standard wire gauge (SWG) number and corresponding diameter of spring wire.


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Chapter Number 7

Design Parameter`s and

Limitations

1. OUTPUT POWER CALCULATIONS

2. DESIGN SPECIFICATIONS

3. SPROCKET WHEEL AND CHAIN

4. SPRINGSSPUR GEARS


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1. OUTPUT POWER CALCULATIONS:- Let us consider,

The mass of a vehicle moving over the speed breaker = 10Kg (Approximately)

Height of speed brake = 10 cm

Work done = Force x Distance

Here,

Force = Weight of the Body

= 10 Kg x 9.81

= 98.1 N

Distance traveled by the body = Height of the speed brake

= 10 cm

Output power = Work done/Sec

= (89.1 x 0.10)/60

= 0.1485 Watts (For One pushing force)

Power developed for 1 vehicle passing over the speed breaker arrangement for one

minute

= 0.1485 watts

Power developed for 60 minutes (1 hr) = 8.91 watts

Power developed for 24 hours = 213.84watts


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Velocity Ratio of Chain Drives:

The velocity ratio of a chain drive is given by

𝑉. 𝑅. =𝑁1𝑁2

=𝑇2𝑇1

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. =𝑁1𝑁2

= 𝑇2𝑇1

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


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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 = 2 mm

• Mean dia of coil = 12 mm

• Free length of spring = 300mm

5. SPUR GEARS:- • No Of Teeth On Rack = 36

• Rack Length = 230mm

• No Of Teeth On Pinion =36

• Diameter Of Pinion Gear =270mm

• Thickness of pinion gear =20mm

• Length of speed breaker =290mm

• Width of speed breaker =220mm

• Height of speed breaker =130mm


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COST ANALYSIS:-

Cost:

It is defined as the amount of expenditure occurred in bringing out a product.

Cost is expressed along with the atom viscose of bicycle axle Rs.15/- per axle cost of

bearing Rs.150/.Bearing.

Cost of Elements:

The different cost is placed in three categories.

Material Cost

Labor Cost

Other Expenses

Material Cost:

It is the cost on the material, which is converted into product. This is of two types:

Direct Material Cost

It is cost of all those materials which when worked upon become the integral part of the

product. For example lathe bed casting when machined, heat treated and grounded

becomes a lathe bed.

Indirect Material Cost

All those materials, which are consumed during manufacturing for processing a product,

but do not become part of product. For example electric energy, cutting oil, grease, water

and cotton waste.

Prime Cost

This is also known as direct cost. Prime Cost = direct material cost + direct labor cost and

expenses

Factory Cost

This is also known as factory cost. Factory cost = prime cost + factory expenses.


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Office Cost

This is also known as production office cost = factory cost + administrative expenses + all

and the expenses.

Total Office

This is also known as selling cost. Total cost = office cost + selling and distribution expenses

Selling price of product

Selling cost = total cost + profit loss

Brake Even Chart:

This is graphical illustration to show loss and profit region. This type is deciding the no of

units to be made at which three is neither any loss nor any profit. It is arrived it a following

Fixed Cost:

This is the cost, independent of product. This cost is three even if the product is nil.

Labor cost

It is the labor which converts raw material into product which tools and machines and

hence the cost over the labor

Direct Labor cost

All the labors are working on the machines and material who can be identified with the

product, are called direct labor and hence cost over them. For example, a lathe operator,

a milling man.

Indirect labor cost

All the labors that help in manufacturing cycle but cannot be identified directly with a

particular product and hence cost over them. For example, Sweepers, gate keepers, rigors,

store keepers etc.

Other Expenses

All those expenses not covered under labor and material cost fall under this category.

They are also of two types.


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Direct expenses

All those expense, which can be assigned to a particular job, are placed in this category.

This will include the following.

Expenses incurred in preparing design, drawing and process sheet.

Cost of jobs, fixtures is any made / hired for the job.

Patterns used for the mold.

Any consultation fee paid for the job.

Indirect expenses

All other expenses left out for above. They make a major part of the cost. These expenses

are of following type.

Factory Expenses

This is also known as “factory over heads”, factory on cost on work on cost.

Administrative expenses

This is also known as office on cost.

Selling expenses

Distribution expenses

R & D expenses

Selling price of product, It can be calculated as follows:


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Selling price of pipe bending machine:

Prime Cost:

Prime cost = material cost + labor cost + other cost.

=Rs,4500/.

Bearing, cutting tool, screw etc. = Rs500/.

Material cost = Rs3500.

Labor cost = 15hrs (no of machine operators * Rs50 per hour)

= 15 hour (5* Rs50 per hour)

= 500 Rs.

Other expenses:

= manufacturing process (painting + machines and energy consumed)

Other expenses = 500 + 15hours 10Rs/hour

= 650/.

Factory Cost:

Factory cost = prime cost + factory expenses

= 4500 + 500 = Rs5000.

Total cost:

Total cost = office cost + selling cost and distribution cost =Rs 10150.

Selling cost:

Selling cost = total cost + profit lose.

= 10150 + (10 % * total cost)

= 10150 + (10 * 10150/100) = Rs. 11155

By adding the general sales taxes = selling cost + 16% = 11155 + 16%

= Rs. 12939

Selling Cost = Rs. 12939


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REFERENCES:-

I. Department of Mechanical Engineering Queen’s Building, University

of Bristol, Bristol, BS8 1TR, UK

II. A Textbook of Machine Design by R.S.KHURMI AND J.K.GUPTA.

III. Automobile Engineering , KirpalSingh.

IV. Automobile Engineering, S.M.Pandey& K.K. Shah.

V. www.wikipedia.com.

VI. Shigley Tata McGraw hills (Machine Design).

VII. Generation of Electricity through Speed Breaker Mechanism.

(Alok Kumar Singh, Deepak Singh, Madhawendra Kumar , Vijay Pandit,

Prof.SurendraAgrawal).

VIII. EVERY SPEED BREAKER IS NOW A SOURCE OF POWER.

(ASWATHAMAN.V ELECTRONICS AND COMMUNICATION

ENGINEERING SONA COLLEGE OF TECHNOLOGY SALEM, INDIA).

(PRIYADHARSHINI.M ELECTRONICS AND COMMUNICATION

ENGINEERING SONA COLLEGE OF TECHNOLOGY SALEM, INDIA).

http://www.wikipedia.com/

GENERATION OF ELECTRICITY THROUGH SPEED BREAKER

Engineering

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