Speed Breaker Power Generation

PROJECT REPORT SPEED BREAKER POWER GENERATION

In partial fulfillment of requirements for the degree of Bachelor of Technology In Mechanical Engineering Submitted By: ALPHIN PEREIRA MCE17ME022 KRISHNA DAS V.S. MCE17ME068 SABARICHAND S. MCE17ME097 Under the guidance of Prof. ELVIN ROY

Department of Mechanical Engineering Marian Engineering College, Trivandrum [2020 – 2021]

MARIAN ENGINEERING COLLEGE, TRIVANDRUM DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE Certified that this is a bonafide record of the Project Work titled SPEED BREAKER POWER GENERATION done by ALPHIN PEREIRA MCE17ME022, KRISHNA DAS V.S. MCE17ME068 and SABARICHAND S. MCE17ME097 of final year B. Tech Mechanical Engineering in partial fulfillment of the requirement for the award of Bachelor of Technology Degree in Mechanical Engineering under the APJ Abdul Kalam Technological University during the academic year 2020-21.

Prof. Elvin Roy

Prof. Rajaneesh R Chandran

Project Guide

Project Coordinator

Assistant Professor

Assistant Professor

Prof. Arun J Head of Department

AKNOWLEDGEMENTS

We thank almighty God for giving us the confidence and presence of mind throughout this endeavor and completing this seminar without any problem.

We would like to express our sincere gratitude and heartfelt indebtedness to our guide Prof. Elvin Roy and our project coordinator Prof. Rajaneesh R. Chandran for their valuable guidance, contest encouragement and creative suggestions during the course of the seminar and in the preparation of this report.

We are also thankful to Prof. Arun J, Head of Department, Department of Mechanical Engineering for the valuable suggestion and motivation in completing this seminar.

We are also thankful to our principal Dr. Ruby Abraham, for giving us this opportunity to present our seminar in this institution.

We offer our deep felt to all the teaching and non-teaching staff of the department for supporting us without any hesitation whenever we needed.

We are also grateful to our parents, for their endless support and encouragement.

Last but not the least we express our heartfelt to all our colleagues for their wholehearted support and encouragement to our seminar.

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ABSTRACT

The project is about the design and manufacturing of speed breaker power generator. In this project we are trying to utilize one such source. Electricity is generated by replacing the traditional speed breakers with some simple mechanism. As vehicles pass over the speed breakers, the speed breaker itself goes down due to weight of the vehicle which results in displacement of a rack gear which rotates the pinion connected to shaft of the generator which in turn produces electricity. This method is an effective way to produce electricity as the numbers of vehicles on the road are ever increasing. Also, the cost of fabrication of the model is low. It can be effectively placed near traffic lights, at the entrance of parking lots and any other place where the traffic density is high. As vehicle passes over it, it starts moving. This method provides an efficient way to generate electricity from the kinetic energy of moving vehicles in roads, highways, parking lots etc. In this report I explain in detail the various stages of research, design and manufacturing which was involved in the construction of various components such as springs, generator, rack and pinion mechanism. In short, this report includes an overview of design and research undertaken in making the project successful.

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CONTENTS CHAPTER NO

TITLE

PAGE NO

1

Introduction

1

1.1 Types of mechanisms

1

1.2 Used materials

2

1.3 Used methods

4

1.4 Literature survey

5

Components of rack & pinion mechanism

7

2.1 Parts of the system

7

2.1.1 Metal sheets

7

2.1.2 Rack and pinion

7

2.1.3 Freewheel

8

2.1.4 Flywheel

8

2.1.5 Generator

9

2.1.6 Battery and battery charger

9

2.1.7 Inverter and step-up transformer

10

2.1.8 Springs

10

Analysis

11

3.1 Stress Analysis

11

3.2 Deformation Analysis

12

3.3 Dimensions

14

Construction

15

4.1 Working

16

4.2 Calculations

16

4.3 Advantages

18

4.4 Applications

18

5

Conclusion

19

6

References

20

2

3

4

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LIST OF FIGURES CHAPTER NO 1

2

3

4

FIGURE TITLE

PAGE NO

1.1a Rack & Pinion

2

1.1b Roller mechanism

2

1.1c Crank Shaft mechanism

2

1.1d Air piston mechanism

2

1.2a Galvanized metal sheets

3

1.2b Stainless steel rods

3

1.2c Compression springs

3

1.3a Milling machine

4

1.3b Milling cutter and work piece

4

1.3c Welding diagram

4

2.1.1a Base plate

7

2.1.1b Top plate

7

2.1.2 Rack and Pinion

7

2.1.3 Freewheel

8

2.1.4 Rim Type Flywheel

8

2.1.5 Alternator/AC generator

9

2.1.6a Battery

9

2.1.6b Battery charger/AC-DC Converter

9

2.1.7a Inverter

10

2.1.7b Step up transformer diagram

10

2.1.8 High tensile strength spring

10

3.1a Hump

11

3.1b Pinion

11

3.1c Flywheel

11

3.1d Rack

12

3.2a Pinion

12

3.2b Rack

12

3.2c Flywheel

13

3.2d Spring

13

4 Assumed form of the project

15

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Chapter 1 INTRODUCTION The conventional sources of energy are generally non-renewable sources of energy, which are being used since a long time. To improve the power generation technologies and to make them more sustainable, non – conventional technologies have been discovered. Energy generated by using wind, tides, solar, geothermal heat, and biomass including farm and animal waste is known as nonconventional energy. All these sources are natural, renewable or inexhaustible and do not cause environmental pollution and are eco-friendly. More over they do not require heavy expenditure. The non-conventional sources of energy are abundant in nature. Most of the non – conventional sources have been boons at hand only to the well developed countries. The developing countries that lag behind in technical assets and financial limitations are striving to install the technologies of the latest trends and advanced versions. With the vast development of the technologies and understanding them, many other creative techniques of power generation have been emerged. The newly developed techniques are aimed at cost effectiveness. Thus they become more affordable to the countries like India, where installation cost and space occupancy are serious issues. One such creative technique is power generation through speed breakers.

1.1. Types of mechanisms The idea is to tap the potential energy that a vehicle would acquire when it is lifted over the speed breaker as it rolls over it. Some of the types of speed breakers with which electricity can be generated are: •

Rack and Pinion mechanism

•

Roller mechanism

•

Lever mechanism

•

Crank shaft mechanism

•

Air piston mechanism

This method is achieved by the use of rack and pinion mechanism. The rack and pinion mechanism has it’s advantages over the other non-conventional methods like roller mechanism, lever mechanism, air piston mechanism and crank shaft mechanism. When compared with roller mechanism, the slip of the tyres over the speed breaker is avoided as is possible in roller mechanism. The slip of the tyres would pose more trouble to the vehicle user than the power 1

generated. Our project is to completely utilize the technique of using rack and pinion mechanism for power generation.

Fig 1.1b Roller mechanism

Fig 1.1a Rack & Pinion

Fig 1.1c Crank Shaft mechanism

Fig 1.1d Air piston mechanism

1.2. Used materials Galvanised metal sheets: These metal sheets are used as the base plate and the top plate of the whole setup. As it is galvanised no rusting occurs so this idea is favourable in moist and rainy places too.

Stainless steel bars: These components are the ones that are used to construct the frame of the setup. All the parts of the project needs to be placed well in place and protected and hence a strong corrosion and heat resistant material is needed.

2

Compression springs: For the speed breaker to return to it’s initial position springs are necessary.

Compression type are used in this case. The spring material type adopted for this method is hardened steel. The springs should be able to support the weight of a vehicle. For this prototype we will be considering the springs to support the weight of a motorcycle.

Fig 1.2a Galvanized metal sheets

Fig 1.2b Stainless steel rods

Fig 1.2c Compression springs Other components like alternator, battery, inverter can be bought. Gears can be bought or manufactured. The manufacturing related methods that are used in this project are as follows.

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1.3. Used methods Milling: Milling is carried out for the manufacture of gears. The type of milling that is used to produce gears is called Form milling. In form milling, the cutter called a form cutter travels axially along the length of the gear tooth at the appropriate depth to produce the gear tooth. After each tooth is cut, the cutter is withdrawn, the gear blank is rotated and the cutter proceeds to cut another tooth. The process continues until all teeth are cut. Each cutter is designed to cut a range of tooth numbers. The precision of the form-cut tooth profile depends on the accuracy of the cutter and the machine and its stiffness.

Fig 1.3a Milling machine

Fig 1.3b Milling cutter and work piece

Welding: Welding is a fabrication process that joins materials, usually metals or thermoplastics, by using high heat to melt the parts together and allowing them to cool, causing fusion. Heat at a high temperature causes a weld pool of molten material which cools to form the join, which can be stronger than the parent metal.

Pressure can also be used to produce a weld, either alongside the heat or by itself and that process is called pressure welding or solid state welding. The stainless steel bars needs to be welded together to form the main frame. The frame should be able to support and keep all the components of the project in place.

Fig 1.3c Welding diagram 4

1.4 Literature survey 1.4.1 THE BURGER KING ON U.S. HIGHWAY, CUSTOMERS PULLS IN AND OUT ALL DAY, AND AT LEAST 100,000 CARS VISIT THE DRIVE-THRU EACH YEAR. AND A NEWLY INSTALLED, MECHANIZED SPEED BUMP WILL BOTH HELP THEM SLOW DOWN AND HARVEST SOME OF THAT COASTING ENERGY. •

The weight of a car is used to throw a lever, explains Gerard Lynch, the engineer behind the MotionPower system developed for New Energy Technologies, a Maryland-based company.

•

The instantaneous power is 2,000 watts at five miles-per-hour, but it's instantaneous which means some form of storage will be required.

1.4.2 JOURNAL OF ENGINEERING RESEARCH AND STUDIES.PRODUCE ELECTRICITY

BY THE USE OF SPEED BREAKERS SHAKUN SRIVASTAVA, ANKIT ASTHANA, DEPARTMENT

OF

MECHANICAL

ENGINEERING,

KANPUR

INSTITUTE

OF

TECHNOLOGY, KANPUR •

The rotor (rotating shaft) is directly connected to the prime mover and rotates as the prime mover turns.

•

The rotor contains a magnet that, when turned, produces a moving or rotating magnetic field.

The rotor is surrounded by a stationary casing called the stator, which contains the wound copper coils or windings.

•

When the moving magnetic field passes by these windings, electricity is produced in them. By controlling the speed at which the rotor is turned, a steady flow of electricity is produced in the windings.

•

These windings are connected to the electricity network via transmission lines.

•

IIT Guwahati has evaluated the machine and recommended it to the Assam ministry of power for large scale funding. IIT design department says it is a „very viable proposition‟ to harness thousands of megawatts of electricity untapped across the country every day. A vehicle weighing 1,000 kg going up a height of 10 cm on such a rumble strip produces approximately 0.98 kilowatt power.

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•

So one such speed-breaker on a busy highway, where about 100 vehicles pass every minute, about one kilo watt of electricity can be produced every single minute. The figure will be huge at the end of the day. A storage module like an inverter will have to be fitted to each such rumble strip to store this electricity.

•

The cost of electricity generation and storage per megawatt from speed-breakers will be nearly Rs 1 crore as opposed to about Rs 8 crores in thermal or hydro power stations.

1.4.3 JOURNAL OF ENGINEERING RESEARCHANDSTUDIES.PRODUCE ELECTRICITY

BY THE USE OF SPEED BREAKERS. ASWATHAMAN.V, ELECTRONICS AND COMMUNICATION ENGINEERING SONA COLLEGE OF TECHNOLOGY, SALEM, INDIA •

This paper attempts to show how energy can be tapped and used at a commonly used systemthe road speed breakers. The number of vehicles passing over the speed breaker in roads is increasing day by day.

•

There is great possibility of tapping this energy and generating power by making the speedbreaker as a power generation unit. The generated power can be used for the lamps, near the speed breakers. The utilization of energy is an indication of the growth of a nation.

•

For example, the per capita energy consumption in USA is 9000 KWh (Kilo Watt hour) per year, whereas the consumption in India is 1200 KWh (Kilo Watt hour). One might conclude that to be materially rich and prosperous, a human being needs to consume more and more energy.

•

A recent survey on the energy consumption in India had published a pathetic report that 85,000 villages in India do not still have electricity. Supply of power in most part of the country is poor. Hence more research and development and commercialization of technologies are needed in this field.

•

India, unlike the top developed countries has very poor roads. Talking about a particular road itself includes a number of speed breakers. 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.

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Chapter 2 COMPONENTS OF RACK AND PINION MECHANISM 2.1 Parts of the system The following are the parts of the speed breaker working on the rack and pinion mechanism.

2.1.1 Metal sheets Certain galvanized sheets are used for the platform of the speed breaker for the vehicles to pass over. These are also used as the base plates to support the whole mechanism. The plates will have vertical supports to guide the springs installed on it in perfect vertical direction when the mechanism is in work.

Fig 2.1.1a Base plate

Fig 2.1.1b Top plate

2.1.2 Rack & Pinion This is the core element of the whole system.

A rack and pinion is a type of linear actuator that comprises a circular gear (the pinion) engaging a linear gear (the rack), which operate to translate rotational motion into linear motion. Driving the pinion into rotation causes the rack to be driven linearly, driving the rack linearly will cause the pinion to be driven into a rotation. For this case its the

Fig 2.1.2 Rack and Pinion

latter.

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2.1.3 Freewheel Freewheel is used between the pinion and Flywheel. It is responsible for maintaining the rotation of the flywheel in one direction even after the load application.

Fig 2.1.3 Freewheel

2.1.4 Flywheel Flywheel is the component that is used to provide constant angular motion of the shaft. The speed breaker won’t be actively moving constantly as it is only possible when a vehicle passes over it.

So after a vehicle moves over it the flywheel will help in rotating the shaft a little more longer and thereby helping in developing some extra power.

Fig 2.1.4. Rim Type Flywheel 8

2.1.5 Generator An AC generator or an alternator is used in this system to convert the mechanical energy from the rotational motion of the shaft into electrical energy. AC generator is used instead of DC as it has higher efficiency and does not suffer from losses like copper, eddy current, mechanical and hysteresis. The generator shaft will be smaller in size than that of the flywheel shaft and therefore the rotation will be more.

Fig 2.1.5 Alternator/AC generator

2.1.6 Battery & Battery charger The battery stores the electrical energy coming out of the generator. But the current that is coming out of it is AC. Therefore the battery charger converts AC into DC supply and proceeds it into the battery where it is stored. Lithium and Lead acid batteries are prominently used in renewable energy production as it has long life and less maintenance is required. Lithium batteries has high discharge and recharge rates.

Fig 2.1.6a Battery

Fig 2.1.6b Battery charger/AC-DC Converter 9

2.1.7 Inverter & Step up transformer The power coming out of the battery is direct current which will have to be converted to AC. The 12V DC coming from the battery is converted to 15V AC using the inverter and then the step up transformer steps up this to 220V AC. In most cases the inverter and the step up transformer will be a single unit. This final power output can then be used to power up AC appliances like street lights, traffic signals, etc.

Fig 2.1.7a Inverter Fig 2.1.7b Step up transformer diagram

2.1.8 Springs Springs are installed beneath the speed breaker top plate to help it in returning to its initial position once a vehicle has passed over it so as to be ready for the next vehicle. The springs used are compression springs and different compressive strength springs should be used in different places depending on the type of vehicles a particular place has most. For eg. High compressive strength is required for the springs in areas near harbors where heavy trucks might pass through whereas in normal cities lesser springs are needed.

Fig 2.1.8 High tensile strength spring 10

Chapter 3 ANALYSIS 3.1Stress analysis Fig 3.1a Hump

Fig 3.1b Pinion

Fig 3.1c Flywheel

11

Fig 3.1d Rack

3.2Deformation Analysis Fig 3.2a Pinion

Fig 3.2b Rack

12

Fig 3.2c Flywheel

Fig 3.2d Spring

The above figures are screenshots of the components after being analysed using Ansys workbench and Fusion 360. Under the category 3.1 is the stress analysis data of hump, pinion, flywheel and rack. From the scale provided alongside the components it is understood that red refers to higher stress input and is the tensile stress. The blue indicates negative value and that indicates compressive stress. The unit of stress used in this analysis is Pascal.

In the category 3.2 the screenshots are of the deformation analysis done on the components.

The figures shows the deformation data of pinion, rack, flywheel and spring. Also here from the scale given alongside we can understand that red depicts higher deformation and blue is no deformation at all. But the highest value is still a very small value and therefore the deformation experienced by the component is negligible.

From the data obtained from this analysis the model is safe and possible for execution.

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3.3 Dimensions ➢ Hump: •

Length = 3000mm

•

Width = 279mm

•

Height of spring supports = 450mm

•

Radius of curvature = 204.6mm

➢ Rack: •

Length = 300mm

•

Number of teeth on each side = 16

•

Whole depth = 10.935mm

•

Thickness = 20mm

➢ Pinion •

Pitch diameter = 113.954mm

•

Number of teeth = 18

•

Module = 6

•

Whole depth = 11.386mm

•

Thickness = 20mm

➢ Flywheel: •

Outer diameter = 300mm

•

Inner diameter = 280mm

•

Thickness = 20mm

•

Mass = 9.6kg

➢ Spring •

Outer ring diameter = 40mm

•

Wire thickness = 4mm

•

Free length = 300mm

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Chapter 4 CONSTRUCTION

The main component of the system is the rack and pinion mechanism. It is placed beneath the speed breaker hump. The hump is made using galvanized steel sheets. The rack is connected to the underside of the hump. This rack is kept in contact with the two pinions on either of it’s sides. The pinions help in converting the linear motion of the rack into rotary motion. One of the pinion is connected with the flywheel via a shaft. The freewheel is installed between the pinion and the flywheel to make sure the pinion causes only one directional motion to the flywheel. The flywheel is connected to the generator shaft by a belt or a chain. The generator shaft will be made smaller than the flywheel shaft to get more rotations. The generator is connected to the battery by a AC to DC converter. The battery is in turn connected to inverter and step up transformer which results in the final output. The springs are installed beneath the speed hump and is firmly placed at the base.

The springs are supported by a shaft acting as a guideway for it to translate it’s motion. The base plate and the top plate will have groove or any kind of such support to prevent the spring from wobbling or buckling up. This whole setup is protected and held in place with the help of a strong stainless steel frame. Rubber paddings can be provided in the gaps between the hump and the road to prevent any dirt or water from getting into the system which will already be protected by fully covered frame

Fig 4 Assumed form of the project 15

4.1 Working When a car reaches the speed breaker, it applies its weight on it. The rack connected with the speed breaker will move downwards and the two pinions meshed across the rack will rotate. The flywheel is connected via the shaft of one of the pinions. So the rotation of the pinion will induce motion on the shaft and the flywheel. The flywheel ensures the constant angular motion of the shaft and it will help continue rotating even after the load application.

The springs underneath the speed breaker will help push the hump back into it’s initial position once the vehicle has passed over it. And when that happens it will rotate the pinions again, but due to the presence of the freewheel in between the pinion and the flywheel the upward movement of the rack will not induce any reverse rotary motion of the pinion or the flywheel. The flywheel keeps the rotation of the shaft in uniform angular motion. The flywheel is coupled with the AC generator, the battery charger converts AC output into DC supply and proceeds it into the battery where it is stored. The power coming out of the battery is direct current which will have to be converted to AC. The 12V DC coming from the battery is converted to 15V AC using the inverter and then the step up transformer steps up this to 220V AC. Support platforms supports the springs & supporting bars support the whole mechanism.

4.2 Calculations Assume vehicle mass, m = 1500kg Allowable displacement of bump is maximum of 15 cm Assuming a vehicle is moving at v = 10 km/hr = 2.7m/s Kinetic energy possessed by the vehicle = 1/2 mv2= 5467.5J When the vehicle comes in contact with the hump the force applied is, kinetic energy / displacement = 5467.5 / 0.15 = 36450N

This force is acting only for a very short time because the time taken for one set of wheels to move over the hump is very small and the motion of bump beyond 15cm is also restricted.

So the time taken is assumed as 2 seconds.

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The force applied by the vehicle on the hump is transmitted to the rack. The rack transfers this force to the pinions tangentially thereby causing them to rotate.

Pitch diameter of pinion = 113.954mm; So radius, r = 56.977mm θ = 90, because the rack applies force tangentially onto the pinion The turning moment (Torque) of the pinion, T = r.F.sinθ = 0.0569 * 36450 * sin90 = 2074.005Nm

For each displacement of bump, rack displaces by 15 cm and pinion along with the flywheel which is on the same shaft completes 0.42 rotation which is θ = 151.2° Work done = T.θ = 2074.005 * 151.2 degree = 2074.005 * 2.63 radians = 5454.63J

Power o/p = Work done / time taken for the angular displacement = 5454.63 / 2 = 2727.316w = 2.72kw = 2.72 * 2 (For 2 sets of wheels) = 5.44kw for one vehicle of mass 1500kg

Due to the Covid constraints of this year the project fabrication was not possible. The power output of the generator is only possible by working the actual physical model. Simulated software conditions is only good for analysing the model design and the mapping of movement of the components.

As a result the power output obtained here is the power developed at the flywheel shaft of the device. This power will then be transferred to the generator to convert into usable form of electric energy.

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4.3 Advantages •

We can have annual electricity generation with the help of this method without depending on other factors.

•

Power generation takes place reasonably and by using non-conventional energy sources which will help to preserve the conventional energy sources for our adjacent future demand.

•

There is no usage of any fossil fuel hence electricity is generated by renewable means.

•

Pollution less energy generation.

•

Simple construction, mature technology and easy maintenance.

•

This method requires less measure of floor area and also the traffic is not obstructed.

•

It is economical and not difficult to install.

•

This method is promising due to its good efficiency and energy recovery criteria.

4.4 Applications • Street Lights can be provided with electricity generated by this method.

• Traffic Signals can be run by using the electricity generated by this method.

• Sign boards on the roads can be lit with the help of this method.

• Boards near the bus-stops can be highlighted by using this method generated electricity.

• This method can also be used on the check posts on highways.

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Chapter 5 CONCLUSION This paper introduces another innovative method of green power generation in order to contribute towards the development of the country by enriching it with utilization of available resources in more useful manner. Due to population explosion, the current power generation has become insufficient to fulfil our requirements. In the upcoming days, as demand of electricity is increasing rapidly, it will prove a great boon to the country and also to the world, since it will save a lot of electricity of powerplants which is wasted in illuminating the street light. This research can be used to develop our country by enhancing more and more utilization of its sources in more appropriate and proficient manner. The development of a country is directly proportional to the way in which it uses power supply sufficiently and efficiently. Now is the need of an hour when these types of inventive ideas should be brought into practice. This idea not only provides an alternative, but also adds to the economy of the country. Development of every country is the development of the world.

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Chapter 6 REFERENCES [1] Kiran Kolhe and Amar Pandhare, 18 June 2017, Vol.7, No.3 (June 2017), Electric Power Generation System from Speed Breaker by using Rack and Pinion Mechanism [2] M.Sailaja, M. Raja Roy, S. Phani Kumar, International Journal of Engineering Trends and Technology (IJETT) – Volume 22 Number 8-April 2015, Design of Rack and Pinion Mechanism for Power Generation at Speed Breakers [3] Laukik Kharche, Kalpesh Jadhav, Pranay Gawas, Chaitali Gharat, International Research Journal of Engineering and Technology (IRJET) - 2019, SPEED BREAKER POWER GENERATION [4] G.Ramakrishna Prabu, G.Ethiraj, International Journal of Advanced Research in Electrical, Electronics and Instrumentation Engineering, Vol. 4, Issue 5, May 2015, Electricity Generation by Speed Breaker

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