CHAPTER 1: INTRODUCTION

Before starting we have one question to all, who is really very happy with the current situation of the electricity in Pakistan? We suppose no one. So this is our step to improve the situation of electricity with an innovative and useful concept i.e. Generating Electricity from a Speed breaker First of all what is electricity means to us? Electricity is the form of energy. It is the flow of electrical Power. Electricity is a basic part of nature and it is one of our most widely used forms of energy. We get electricity, which is a secondary energy source, from the conversion of other sources of energy, like coal, natural gas, oil, nuclear power and other natural sources, which are called primary sources. Many cities and towns were built alongside water falls that turned water wheels to perform work. Before electricity generation began slightly over 100 years ago, houses were lit with kerosene lamps, food was cooled in iceboxes, and rooms were warmed by wood-burning or coal-burning stoves. Direct current (DC) electricity had been used in arc lights for outdoor lighting. In the late-1800s, Nikola Tesla pioneered the generation, transmission, and use of alternating current (AC) electricity, which can be transmitted over much greater distances than direct current. Tesla's inventions used electricity to bring indoor lighting to our homes and to power industrial machines.

Why Use Speed Bumps to Generate Energy?

An energy crisis is any great bottleneck (or price rise) in the supply of energy resources to an economy. It usually refers to the shortage of oil and additionally to electricity or other natural resources. An energy crisis may be referred to as an oil crisis, petroleum crisis, energy shortage, electricity shortage electricity crisis. While not entering a full crisis, political riots that occurred during the 2007 Burmese anti-government protests were initially sparked by rising energy prices. Likewise the Russia-Ukraine gas dispute and the Russia-Belarus energy dispute have been mostly resolved before entering a prolonged crisis stage. Market failure is possible when monopoly manipulation of markets occurs.

A crisis can develop due to industrial actions like union organized strikes and government embargoes. The cause may be ageing over-consumption, infrastructure and sometimes bottlenecks at oil refineries and port facilities restrict fuel supply. An emergency may emerge during unusually cold winters. Emerging shortage crisis that currently exist include; Oil price increases since 2003 - Cause: increasing demand from the U.S and China, the falling state of the U.S. dollar, and stagnation of production due to the U.S. occupation of Iraq. Iraq is #3 in the world (besides Saudi Arabia and Iran) for its oil reserves. However some observers have stated the global oil production peak occurred in December 2005. If this is correct it is also to blame. 2008 Energy generation has seen significant development in recent years. This investigation describes a new technique for generating energy from the waste kinetic energy of the vehicles at low speed. A conventional speed bump wastes a huge amount of energy when a car is forced to bring itself from a higher, more efficient cruising speed to almost zero. Large cities have a high number of speed bumps - and an equally high level of traffic. For example, London has around 30,000 speed bumps and also has one of the busiest street systems. Just imagine if all these speed bumps are replaced by the new ones, and then imagine to what extent the problem of energy can be solved. Generally when vehicle is in motion it produces various forms of energy like, due to friction between vehicles wheel and road i.e. rough surface heat energy is produced, also when vehicle traveling at high speed strikes the wind then also heat energy is produced which is always lost in environment and of which we cant make use of.or directly we can say that all this energy that we cant make use of is just the wastage of energy that is abundantly available around us. In this project we are just trying to make use of such energy in order to generate an electrical energy. This project will work on the principle of kinetic energy to electrical energy conversion. When a vehicle drives over these speed bumps, a lever is thrown by the weight of the vehicle. The lever turns a flywheel that in turn rotates the rotor of dynamo with the help of a belt. 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. If this model is implemented on a busy highway, the generated electricity can help light up five lamps of 40W. The cost of implementation is only Rs 6,000. So, this method of electricity generation is most reliable and cheaper than any other method of electricity generation.

OUTPUTPOWER CALCULATIONS
Let us consider, The mass of a vehicle moving over the speed breaker 250Kg (Approximately) Height of speed brake =10 cm Work done=Force x Distance Here, Force=Weight of the Body =250 Kg x 9.81 =2452.5 N Distance traveled by the body = Height of the speed brake =10 m Output power=Work done/Sec = (2452.5 x 0.10)/60 =4.0875 Watts (For One pushing force) Power developed for 1 vehicle passing over the speed breaker arrangement for one minute= 4.0875 watts

Power developed for 60 minutes (1 hr) =245.25 watts Power developed for 24 hours=5.866 Kw This power is sufficient to burn four street lights in the roads in the night time.

EXPERIMENTAL INVESTIGATION
The experimental investigation is performed by placing the speed breaker arrangement in a pit with a depth of 75 Cm. Vehicles move over the speed breaker arrangement and the voltage generated is measured by a multimeter and the various readings are plotted in a graph. The graphs are drawn for various parameters as shown below 1. Voltage generated (Vs) speed of vehicle 2. Voltage generated (Vs) Load

LOAD = 270 Kg (Vehicle load + man weight)

B. VOLTAGE GENERATED (VS) LOAD: Speed of vehicle=10km/hr

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.

CHAPTER 2: FLYWHEEL
INTRODUCTION:
For ages flywheels have been used to achieve smooth operation of machines. The early models where purely mechanical consisting of only a stone wheel attached to an axle. Nowadays flywheels are complex constructions where energy is stored mechanically and transferred to and from the flywheel by an integrated motor/generator. The stone wheel has been replaced by a steel or composite rotor and magnetic bearings have been introduced. Today flywheels are used as supplementary UPS storage at several industries world over. Future applications span a wide range including electric vehicles, intermediate storage for renewable energy generation and direct grid applications from power quality issues to offering an alternative to strengthening transmission. One of the key issues for viable flywheel construction is a high overall efficiency, hence a reduction of the total losses. By increasing the voltage, current losses are decreased and otherwise necessary transformer steps become redundant. So far flywheels over 10 kV have not been constructed, mainly due to isolation problems associated with high voltage, but also because of limitations in the power electronics. Recent progress in semiconductor technology enables faster switching and lower costs.

The predominant part of prior studies has been directed towards optimizing mechanical issues whereas the electro technical part now seems to show great potential for improvement. An overview of flywheel technology and previous projects are presented and moreover a 200 kW flywheel using high voltage technology is simulated. When a mass at rest is rotated it acquires kinetic energy. Slowing the mass down or bringing it to rest is achieved by removing kinetic energy. An engineered rotating mass designed specifically to store energy as a result of it motion is called a flywheel. The energy storage system involving a flywheel as its primary unit is called a Flywheel Energy Storage system (FES). Flywheels are used to balance up the energy flow from a smooth running machine delivering energy at a relatively constant level to a load which is varying. Flywheels are also used to produce continuous smooth outputs from engines which are inherently cyclic in nature. Flywheels are generally heavy discs rotating at speed. A flywheel is basically a mechanical version of an electric capacitor when used for short term load balancing. When used for storing energy it is equivalent to a battery.

REQUIREMENT OF FLY WHEEL IN OUR DESIGN:

In our design we are not getting the continuous energy from the pedal and we are applying shock loads to the lever and this energy is not constant throughout the cycle. So as to eliminate or overcome this shock loads we are using the flywheel to supply constant energy to the dynamo.

ADVANTAGES:
1. It is a device, which acts as energy redistributors. 2. This will result in a great reduction in the size and cost of power source. 3. The action is continuous from cycle to cycle.

APPLICATIONS OF FLY WHEEL:

Flywheels are used in IC engines, punching presses, steering machines, riveting machine, crushers, hammering machines.

MATERIAL USED:
Material used for manufacturing of flywheel is cast iron.

COEFFICIENT OF FLUCTUATION OF SPEED:

The difference between tile maximum and minimum speeds during a cycle is called the "maximum fluctuation of speed". The ratio of a maximum fluctuation of speed to the mean speed is called "co-efficient of fluctuation of speed". It is denoted by Cs. Cs = 2(N1N2) / (N1+N2) In terms of speed

ENERGY STORED IN FLY WHEEL:

Kinetic energy of fly wheel, E = I 2 Since I = m k2, E = I k2 2 As speed of flywheel changes from <ox to a>2 the maximum fluctuation of energy. E = = = = Where I M K = = = = maximum KE - minimum KE I 2 Cs m k2 2 Cs 2ECS moment of inertia of fly wheel about the axis mass of fly wheel in Kg radius of gyration of fly wheel in meters mean angular speed in rad/sec.

Cs = co-efficient of fluctuation of speed.

STERSS IN FLY WHEEL RIM:

The major portion of the mass or weight of flywheel of flywheel is concentrated at the RIM. The following stresses are induced in the rim of flywheel. 1. Tensile stress due to centrifugal force 2. Tensile bending stress caused by the restraint of the arms 3. Shrinkage stress due to unequal rate of cooling of casting.

TENSILE STRESS DUE TO CENTRIFUGAL FORCE:

f, = = fr R V = = = = = R2 2 V2 (Where V = R) density of fly wheel material tensile or hoop stress mean radius of fly wheel angular speed of fly wheel linear velocity of fly wheel

TENSILE BEINGING STRESS CAUSED BY RESTRAINT OF THE ARMS:

fb Where n t fb = = = = (19.74 x x V2 x R) / n2 x t number of arms thickness of rim bending stress

STRESS IN FLY WHEEL ARMS:

1. Tensile stress due to centrifugal force ft= y4 x P x V2 2. Bending stress due to the torque transmitted fB = M/Z = T/RQZ (R-r) M Z T R n r = = = = = = maximum bending moment section modulus mum torque transmitted mean radius number of arms radius of the hub

DESIGN OF FLY WHEEL ARMS:

The cross section of the arms is usually elliptical with major axis as twice the minor axis. It is design for maximum bending moment. Therefore Z = II / 32 x b1 x a1 Where a1 b1 M = = major axis minor axis

Maximum bending moment = T/r n(R-r)

Maximum bending stress

B

M/Z = T/R n Z (R-r)

By assuming a1 = 2 x b1 the dimensions of arms may be obtain by above equation. The smaller flywheels (less than 600mm diameter) are not provided with arms. They are made with web type with holes in the web to facilitate handling

CHAPTER 3: BELT DRIVES

INTRODUCTION
Belt drives are widely used in many industries for power transmission since they are cheap and easy to maintain. However they are often a source of vibration due to misalignments, belt resonance, and belt wear. The main purpose of belt drives is to transfer power between machines such as motor and fan. They are subject to rotary and push-pull motions with varying dynamic characteristics. Belts are friction drives, which mean they depend on friction between the belt and pulley/sheave to transmit power.

FACTORS FOR SELECTION OF BELT DRIVE

Following are the various important factors upon which the selection pf a belt drive depends 1. speed of the driving &driven shaft. 2. Speed reduction ratio 3. Powers to be transmitted 4. Central distance between the shaft 5. Positive drive requirement 6. Shaft layout 7. Space available 8 .service condition

FACTORS ON WHICH COFFICIENT OF FRICTION DEPENDS

1. Belt material 2. Pulley material 3. Belt slip 4. Belt speed

COMMON TYPES OF BELT DRIVES

The most common types of belt drives include:

Round belts
Round belts are are generally made of rubber. This type of belt is generally used for light loads, such as in a sewing machine or a vacuum cleaner.

V belts
V belts are arguably the most widely used belts in industry. V belts have a V shaped cross-section, which rests against the side of V pulley under tension. The V shaped cross-section prevents belt from slipping off.

Flat belts
Flat belts are also used to transmit power from one shaft to another. They are generally classified as either small woven endless belts or higher power flat belts. The woven endless belts are especially useful where minimum vibration is required at the driven pulley due to semi-elastic material used in construction. The higher power flat belts are often useful because they eliminate the need to high belt tension used to grip pulleys, which in turn reduces the load on the shaft bearings. The material used for high power flat belts is sticky yet abrasion-resistant rubber compounds.

Timing/toothed belts
Timing belts are toothed belts that use their teeth for power transmission, as opposed to friction. This configuration results in no slippage, and therefore, the driving and driven shafts remain synchronized. Its more expensive to manufacture due to complexity of the belt and pulley shapes.

BELT LENGHT

The length of the belt can be calculated as

lb = ((df + dm) 1.5708 ) + (2 lfm)

where lb = length of belt (mm, inches) df = pulley (sheave) diameter fan (mm, inches) dm = pulley (sheave) diameter motor (mm, inches) lfm = center to center distance of fan and motor pulleys (mm, inches)

BELT VELOCITY
The velocity at which a belt travels may be expressed as v = dm nm / 12 where v = velocity of belt (ft/min) nm = velocity motor (rpm) (2)

Belt Gearing
The relationship between the speed of the motor, the fan and their disc diameters can be expressed as

d f n f = dm n m

HORSEPOWER
If belt tension and belt velocity are known - horsepower transferred can be calculated as Php = T v / 33000 where Php = power (hp) T = belt tension (lbf) v = velocity of belt (ft/min) If torque and revolution per minute are known - horsepower transferred can be calculated as Php = M R / 63000 where Php = power (hp) M = torque (lbf) R = revolutions per minute (rpm)

SPEED RATIO
Speed ratio can be calculated as SR = Rf / Rs where SR = speed ratio Rf = revolutions per minute - fastest machine Rs = revolutions per minute - slowest machine (5)

CH: 3 SHAFTS
Introduction
A shaft is a rotating or stationary component which is normally circular in section. A shaft is normally designed to transfer torque from a driving device to a driven device. If the shaft is rotating, it is generally transferring power and if the shaft is operating without rotary motion it is simply transmitting torque and is probably resisting the transfer of power. A shaft which is not rotating and not transferring a torque is an axle.

Mechanical components directly mounted on shafts include gears, couplings, pulleys, cams, sprockets, links and flywheels. A shaft is normally supported on bearings. The torque is normally transmitted to the mounted components using pins, splines, keys, clamping bushes, press fits, bonded joints and sometimes welded connections are used. These components can transfer torque to/from the shaft and they also affect the strength of the shaft an must therefore be considered in the design of the shaft. Shafts are subject to combined loading including torque (shear loading), bending (tensile & compressive loading), direct shear loading, tensile loading and compressive loading. The design of a shaft must include consideration of the combined effect of all these forms of loading. The design of shafts must include an assessment of increased torque when starting up, inertial loads, fatigue loading and unstable loading when the shaft is rotating at critical speeds (whirling).

Critical (Whirling) Speed Of Shafts

For a rotating shaft there is a speed at which, for any small initial deflection, the centripetal force is equal to the elastic restoring force. At this point the deflection increases greatly and the shaft is said to "whirl". Below and above this speed this effect is very much reduced. This critical (whirling speed) is dependent on the shaft dimensions, the shaft material and the shaft loads. The critical speed is the same as the frequency of traverse vibrations. The critical speed of a shaft is simply

Where m = the mass of the shaft assumed concentrated at single point . k is the stiffness of the shaft to traverse vibrations For a horizontal shaft this can be expressed as

Where y = the static deflection at the location of the concentrated mass Forces
The resulting forces on a shaft resulting from different drive components are listed below

Shaft Deflection It is important that a shaft should not only have the strength to transmit the specified torque and load without the risk of failure but also that shaft deflections due to bending and torque are within acceptable limits. The limiting of the angular /radial deflection is required by the need to reduce vibration and ensure reliable operation of the related components including gears, splines bearings etc. The design procedure for a shaft should therefore include an appraisal of the resulting deflections when the shaft is loaded. If it is deemed necessary to calculate the angular and linear deflections due to bending at critical points then various methods are available.. Some of these methods are identified on webpage Shaft Deflections. Notes on torsional deflections are provided below

Angular Deflection Due to bending

Type of bearing Single-row ball bearings 0,23 Double-row selfaligning ball bearings Cylindrical roller bearings Taper roller bearings Spherical ball bearings 2,0 0,06 0,03 0,5 Max angular deflection []

Spherical roller bearings 12,5 Single-row tapered roller bearings Thrust spherical roller bearings Sliding bearings (b/d < 1) 0,03 2,0 0,05

Radial deflection due to bending

The maximum radial deflection at the teeth for spur gearing = 0.01 * m and for bevel and worm wheels = 0.005 * m (m = module of gear wheel (mm)). The suggested maximum deflection (not at gears) for general engineering = 0.0003 * L and for machine tools = = 0.0002 * L. (L...distance between bearings).

Torsional Angular Deflection

The angular deflection of a shaft is obtained by the equation

In Machinerys handbook 27th ed a safe maximum deflection of 0,26 degrees per m length (0,0045 rads/m) is recommended. Therefore

Indicative Transmittable Torque Values

This table is provided to allow comparison between shafts and is based on very simplistic assumptions with no allowance for fatigue, additional stresses to Bending Moments etc etc.
Shaft Dia mm 30 40 50 60 75 80 100 132 314 614 1060 2071 2513 4909 Pure Torque Nm 1,4 3,3 6,4 11,1 21,7 26,3 51,4 Power (100RPM) kW 20,8 49,3 96,4 166,5 325,3 394,8 771,1 Power (1500RPM) kW

Notes on table values

= The skin torsion stress of a solid round shaft : T= The torque transmitted by the shaft : T = ..D3/16 The table is based on a torsion stress level of 25 N/mm2 Power transmitted by a shaft P = 2 * * T * N (N = Revs /sec) Table power based on pure torque values