Minor Project

Topic: -Energy development from speed breakers

using Rack and Pinion arrangement

Mentor: -Shri Paras Kumar

Group Members:
Ankit Meena
Roll No.- 2K13/ME/038

Shubham Bajaj
Roll No.- 2K13/ME/153
Introduction

Considering the persistent power shortage and the ever-

increasing number of automotive vehicles in a developing
country like India, it is essential to come up with an alternate
source of energy which tackles the above mentioned problem.

The idea behind this project is to utilize the potential energy of

automotive vehicles to generate electricity making use of the
following mechanisms:-
Roller Mechanism
Crankshaft Mechanism
Rack and Pinion Mechanism

All three mechanisms employ the basic principle of converting

mechanical energy into electrical energy. This is achieved
basically by converting the reciprocating motion of the speed
breaker into the rotary motion of the shaft.

This project concentrates primarily on the Rack and Pinion

Mechanism.
Types of Mechanisms

We can develop electricity from speed breakers by using 3 Mechanisms

basically
They are as follows:
1) Roller mechanism
2) Crank-shaft mechanism
3) Rack-pinion mechanism

Roller Mechanism

In this Mechanism, a roller is fitted in between a speed breaker and

some kind of a grip is provided on the speed breaker so that when a
vehicle passes over speed breaker it rotates the roller. This movement of
roller is used to rotate the shaft of D.C. generator by the help of chain
drive which is there to provide different speed ratios. As the shaft of
D.C. generator rotates, it produces electricity. This electricity is stored in
a battery. Then the output of the battery is used to lighten the street
lamps on the road. Now during daytime we dont need electricity for
lightening the street lamps so we are using a control switch which is
manually operated .The control switch is connected by wire to the output
of the battery. The control switch has ON/OFF mechanism which allows
the current to flow when needed.
Main Components used in roller mechanism:
1. Roller
2. Bearings
3. DC motor as generator
Advantages:

Low maintenance cost

Low installation cost
Pollution free power generation.
No manual work necessary during generation.
Simple construction, mature technology and easy maintenance.
No fuel transportation problem.
Energy available all year round.
No consumption of any fossil fuel which is non-renewable source
of energy.

Disadvantages:

Maintenance will be very difficult

Might cause collision
Losses will be more
 Crankshaft Mechanism

The crankshaft is a mechanism that transforms rotary movement into

linear movement, or vice versa. For example, the motion of the pistons
in the engine of a car is linear (they go up and down). But the motion of
the wheels has to be rotary. So, engineers put a crankshaft between the
engine and the transmission to the wheels. The pistons of the engine
move the crankshaft and the movement becomes rotary. Then the rotary
movement goes past the clutch and the gear box all the way to the
wheel.
Components used in crank-shaft mechanism:
1. Connecting rod
2. Springs
3. Crank Shaft
4. A set of gears
5. Bearings
6. AC Generator.

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 nonrenewable source
of energy.

Disadvantages:
Crank-shafts are required to be mounted on bearings which
creates balancing problem.
Mechanical vibrations which in turn damage the bearings.
As bearings are of sliding type, any occurrence of variable
load( which is bit obvious in case of vehicles) leads to balancing
problem
 Rack-Pinion Mechanism

While moving, the vehicles possess some Potential Energy due to its
weight and it is being wasted. This kinetic energy can be utilized to
produce power by using a special arrangement called POWER HUMP. It
is an Electro-Mechanical unit. It utilizes both mechanical technologies
and electrical techniques for the power generation and its storage.
POWER HUMP is a dome like device likely to be speed breaker.
Whenever the vehicle is allowed to pass over the dome it gets pressed
downwards then the springs are attached to the dome and are
compressed and the rack which is attached to the bottom of the dome
moves downward in reciprocating motion. Since the rack has teeth
connected to gears, there exists conversion of reciprocating motion of
rack into rotary motion of gears but the two gears rotate in opposite
direction.. So that the shafts will rotate with certain R.P.M. these shafts
are connected through a set of gears to the dynamos, which converts the
mechanical energy into electrical energy. The conversion will be
proportional to traffic density.
The electrical output can be improved by arranging these POWER
HUMPS in series. This generated power can be amplified and stored by
using different electrical devices. 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 a gear.
This gear is meshed a pinion. As the power is transmitted from the gear
to the pinion, the speed that is available at the gear is relatively
multiplied at the rotation of the pinion. The axis of the pinion is coupled
to a gear arrangement. Here we have two gears with different diameters.
The gear (larger dimension) is coupled to the axis of the pinion. Hence
the speed that has been multiplied at the smaller sprocket wheel is
passed on to this gear of larger dimension. The pinion is meshed to the
gear. So as the gear rotates at the multiplied speed of the pinion, the
pinion following the gear still multiplies the speed to more intensity.
Hence, although the speed due to the rotary motion achieved at the first
gear is less, as the power is transmitted to gears the speed is multiplied
to a higher speed. This speed is sufficient to rotate the rotor of a
generator
The rotor which rotates within a static magnetic stator cuts the magnetic
flux surrounding it, thus producing the electric motive force
(emf). This generated emf is then sent to a bridge rectifier, where the
generated AC current is converted to DC. This regulated emf is now sent
to the lead-acid battery.

Components used in crank-shaft mechanism:

Rack and Pinion Gears
Ball Bearings
Spur Gear
Flywheel
Shaft
Generator
 Advantages:
Using this technology one can get the following benefits:
Low maintenance cost
Low installation cost
Pollution free power generation.
No manual work necessary during generation.
Simple construction, mature technology and easy maintenance.
No fuel transportation problem.
Energy available all year round.
No consumption of any fossil fuel which is non-renewable source of
energy.

Disadvantages:
The rack and pinion can only work with certain levels of friction.
Too high a friction and the mechanism will be subject to wear more than
usual and will require more force to operate.
The most adverse disadvantage of rack and pinion would also be
due to the inherent friction, the same force that actually makes things
work in the mechanism. Due to the friction, it is under a constant wear,
possibly needing replacement after a certain time
 Major Components

Gear
A gear or cogwheel is a rotating machine part having cut teeth, or cogs, which
mesh with another toothed part to transmit torque, in most cases with teeth on the
one gear being of identical shape, and often also with that shape on the other gear.
Two or more gears working in a sequence (train) are called a gear train or, in many
cases, a transmission; such gear arrangements can produce a mechanical advantage
through a gear ratio and thus may be considered a simple machine. Geared devices
can change the speed, torque, and direction of a power source. The most common
situation is for a gear to mesh with another gear; however, a gear can also mesh
with a non-rotating toothed part, called a rack, thereby producing translation
instead of rotation.

General Nomenclature
Rotational frequency, n
Measured in rotation over time, such as RPM.
Angular frequency,

Measured in radians/second. rad/second

Number of teeth, N
How many teeth a gear has, an integer. In the case of worms, it is the number of
thread starts that the worm has.
Gear, wheel
The larger of two interacting gears or a gear on its own.
Pinion
The smaller of two interacting gears.
Path of contact
Path followed by the point of contact between two meshing gear teeth.
Line of action, pressure line
Line along which the force between two meshing gear teeth is directed. It has the
same direction as the force vector. In general, the line of action changes from
moment to moment during the period of engagement of a pair of teeth. For involute
gears, however, the tooth-to-tooth force is always directed along the same line
that is, the line of action is constant. This implies that for involute gears the path of
contact is also a straight line, coincident with the line of actionas is indeed the
case.
Axis
Axis of revolution of the gear; center line of the shaft.
Pitch point
Point where the line of action crosses a line joining the two gear axes.
Pitch circle, pitch line
Circle centered on and perpendicular to the axis, and passing through the pitch
point. A predefined diametral position on the gear where the circular tooth
thickness, pressure angle and helix angles are defined.
Pitch diameter, d
A predefined diametral position on the gear where the circular tooth thickness,
pressure angle and helix angles are defined. The standard pitch diameter is a basic
dimension and cannot be measured, but is a location where other measurements are
made. Its value is based on the number of teeth, the normal module (or normal
diametral pitch), and the helix angle. It is calculated as:

in metric units or in imperial units.

Module or modulus, m
Since it is impractical to calculate circular pitch with irrational numbers,
mechanical engineers usually use a scaling factor that replaces it with a regular
value instead. This is known as the module or modulus of the wheel and is simply
defined as

where m is the module and p the circular pitch. The units of module are
customarily millimeters; an English Module is sometimes used with the units of
inches. When the diametral pitch, DP, is in English units,

in conventional metric units.

The distance between the two axis becomes

where a is the axis distance, z1 and z2 are the number of cogs (teeth) for each of the
two wheels (gears). These numbers (or at least one of them) is often chosen among
primes to create an even contact between every cog of both wheels, and thereby
avoid unnecessary wear and damage. An even uniform gear wear is achieved by
ensuring the tooth counts of the two gears meshing together are relatively prime to
each other; this occurs when the greatest common divisor (GCD) of each gear
tooth count equals 1, e.g. GCD (16,25)=1; If a 1:1 gear ratio is desired a relatively
prime gear may be inserted in between the two gears; this maintains the 1:1 ratio
but reverses the gear direction; a second relatively prime gear could also be
inserted to restore the original rotational direction while maintaining uniform wear
with all 4 gears in this case. Mechanic engineers at least in continental Europe use
the module instead of circular pitch. The module, just like the circular pitch, can be
used for all types of cogs, not just evolvent based straight cogs.
Operating pitch diameters
Diameters determined from the number of teeth and the center distance at which
gears operate.[7] Example for pinion:

Pitch surface
In cylindrical gears, cylinder formed by projecting a pitch circle in the axial
direction. More generally, the surface formed by the sum of all the pitch circles as
one moves along the axis. For bevel gears it is a cone.
Angle of action
Angle with vertex at the gear center, one leg on the point where mating teeth first
make contact, the other leg on the point where they disengage.
Arc of action
Segment of a pitch circle subtended by the angle of action.
Pressure angle,
The complement of the angle between the direction that the teeth exert force on
each other, and the line joining the centers of the two gears. For involute gears, the
teeth always exert force along the line of action, which, for involute gears, is a
straight line; and thus, for involute gears, the pressure angle is constant.

Outside diameter,
Diameter of the gear, measured from the tops of the teeth.
Root diameter
Diameter of the gear, measured at the base of the tooth.
Addendum, a
Radial distance from the pitch surface to the outermost point of the tooth.

Dedendum, b
Radial distance from the depth of the tooth trough to the pitch surface.

Whole depth,
The distance from the top of the tooth to the root; it is equal to addendum plus
dedendum or to working depth plus clearance.
Clearance
Distance between the root circle of a gear and the addendum circle of its mate.
Working depth
Depth of engagement of two gears, that is, the sum of their operating addendums.
Circular pitch, p
Distance from one face of a tooth to the corresponding face of an adjacent tooth on
the same gear, measured along the pitch circle.
Diametral pitch, DP

Ratio of the number of teeth to the pitch diameter. Could be measured in teeth per
inch or teeth per centimeter, but conventionally has units of per inch of diameter.
Where the module, m, is in metric units

in English units
Base circle
In involute gears, where the tooth profile is the involute of the base circle. The
radius of the base circle is somewhat smaller than that of the pitch circle
Base pitch, normal pitch,
In involute gears, distance from one face of a tooth to the corresponding face of an
adjacent tooth on the same gear, measured along the base circle
Interference
Contact between teeth other than at the intended parts of their surfaces
Interchangeable set
A set of gears, any of which mates properly with any other

Types of Gears

Spur Gears

Spur gears or straight-cut gears are the simplest type of gear. They
consist of a cylinder or disk with teeth projecting radially. Though the
teeth are not straight-sided (but usually of special form to achieve a
constant drive ratio, mainly involute but less commonly cycloidal),
the edge of each tooth is straight and aligned parallel to the axis of
rotation. These gears mesh together correctly only if fitted to parallel
shafts.
Bevel Gears

A bevel gear is shaped like a right circular cone with most of its tip cut off. When
two bevel gears mesh, their imaginary vertices must occupy the same point. Their
shaft axes also intersect at this point, forming an arbitrary non-straight angle
between the shafts. The angle between the shafts can be anything except zero or
180 degrees. Bevel gears with equal numbers of teeth and shaft axes at 90 degrees
are called mitre gears.
Helical Gears

Helical or "dry fixed" gears offer a refinement over spur gears. The leading edges
of the teeth are not parallel to the axis of rotation, but are set at an angle. Since the
gear is curved, this angling makes the tooth shape a segment of a helix. Helical
gears can be meshed in parallel or crossed orientations. The former refers to when
the shafts are parallel to each other; this is the most common orientation. In the
latter, the shafts are non-parallel, and in this configuration the gears are sometimes
known as "skew gears".

Worm Gears
Worms resemble screws. A worm is meshed with a worm wheel, which looks
similar to a spur gear.
Worm-and-gear sets are a simple and compact way to achieve a high torque, low
speed gear ratio.

Rack and Pinion

A rack and pinion is a type of linear actuator that comprises a pair of gears, which
convert rotational motion into linear motion. A circular gear called "the pinion"
engages teeth on a linear "gear" bar called "the rack"; rotational motion applied to
the pinion causes the rack to move relative to the pinion, thereby translating the
rotational motion of the pinion into linear motion.

Shaft

A shaft is a rotating element, which is used to transmit power from one place to
another.

Bearings

A bearing is a machine element, which supports another machine element. It

permits a relative motion between the contact surfaces, while carrying the load.
Fly Wheel

The primary function of a fly wheel is to act as energy "Accumulator' simply it

reduces the 'fluctuation' of speed.

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.

Types of springs

These are mainly:

1. Helical springs
2. Torsion springs
3. Involute spring
4. Conical casting laminated or leaf spring.
We are using helical compression springs.

Generator

Electric generator is a device that converts mechanical energy to electrical energy.

A generator forces electric charge (usually carried by electrons) to flow through an
external electrical circuit.
Physical Modelling:

Showing the explode view and whole assembly:

1. Rack 2.Pinon

3. Box
4. Breaker 5. Dome

6. Gear 7. Shaft

8. Motor 9.Spring
Assembly Phase:

Step 1 : Mount all gear on shaft .

Step 2: Assemble the gears and box

Step 3: Attach the rack with pinion

Step 4: Attach the breaker with box.

Step 5: Explode view of whole assembley

Step 6: complete assembly

Fabrication Summary:

1. Frame:

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.

2. Bearing:
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.
3. Shaft:
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.

4. Rack and pinion arrangement:

A rack having thirty-eight teeth which is made up of mild steel is welded
to the speed breaker arrangement. A pinion which is also made up of
mild steel and which has Thirty six teeth is fitted on the shaft initially,
and welded. This pinion tooth is exactly made to mate with the teeth of
the rack...

5. Fly wheel :
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.

6. Generator :
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. To the shaft of the generator, a small gear made of
cast iron is fixed tightly. A larger gear made out of cast iron is machined
well and fitted on the shaft. The teeth on the larger gear are made to
mate rightly with the smaller gear that is fitted to the generator shaft.
Wiring Description:
Coupled the wire of dc generator with dc holder and then these
wires are coupled with the battery terminals.
Coupled the battery positive and negative with inverter (DC to
AC).
Inverter input coupled with ac bulb and voltmeter.

Circuit Diagram:
Components with their specifications:
Name of the Component Specification
S.No
.
Motor: (i)Voltage : 12
1 (ii)Type: D.C. Generator
(iii) RPM: 1200rpm
Gear: (i)Material : Mild Steel
2 (ii) No. of teeth : 56(big gear)
(iii)No. of teeth : 48(small gear)
(iv) Type: Spur gear
(v)No.of gear used:2
Spring : (i) Load bearing capacity :6- 7kg
3 (ii)Material: Mild Steel
(iii)Total displacement: 2 inch
Chain & Sprocket (i) Number of teeth on big
4 sprocket :48
(ii)Number of teeth on small
sprocket 19
(iii)Distance between the center
16 cms
Bearing (i) Type: Rolling contact bearing
5 (ii) Bearing no. N40
Shaft (i)Diameter : 8mm
6 (ii) Material : Mild steel
(iii) Length : 381mm
Calculations:

The mass of a vehicle = 150Kg

Height of speed brake =10 cm
Work done=Force x Distance
where, Force = Weight of the Body = 150 x 9.81m/s = 1471.5 N
Distance travelled by the body = Height of the speed brake =10 cm
Output power= (1471.5 x 0.1)/60 = 2.452 Watts (For One pushing
force)
Power developed for 1 vehicle passing over the speed
breaker arrangement for one minute = 2.452 watts
Power developed for one hour =147.12 watts
Power developed for one day = 3.531 kw
Power developed for one month = 105.9 kw
Power developed for one year = 1271.16 kw
Reference:

EVERY SPEED BREAKER IS NOW A SOURCE OF POWER 2010

International Conference on Biology, Environment and Chemistry
IPCBEE vol.1 (2011) (2011) IACSIT Press, Singapore
CP Racks & Pinions Catalog Numbers of KHK stock gears
PRODUCE ELECTRICITY BY THE USE OF SPEED BREAKERS Journal of
Engineering Research and Studies E-ISSN 0976-7916JERS/Vol.II/
Issue I/April-June, 2011/163-165
Speed Bumps Harvest Electricity from Moving Cars by Sarah Parsons,
09/08/09
Design of Machine Elements by R.S Khurmi
Mechanics of Materials by Shigley
Booklet of ASME standards for selection of bearings
Wikipedia