Professional Documents
Culture Documents
Project Supervisors
Col. Dr. Syed Waheed Ul Haq
Col. Dr. Mazhar Iqbal
Asst. Prof. Rehan Ahmed Khan
---------------------------------Project Supervisors
Col. Dr. Syed Waheed Ul Haq
Col. Dr. Mazhar Iqbal
Asst. Prof. Rehan Ahmed Khan
Department of Mechanical Engineering
College of Electrical and Mechanical Engineering,
NUST.
---------------------------------Head of Department
Col. Dr. Syed Waheed Ul Haq
Department of Mechanical Engineering
College of Electrical and Mechanical Engineering,
NUST.
July, 2013
College of Electrical and Mechanical Engineering
National University of Sciences and Technology
DECLARATION
We hereby declare that no portion of the work referred to in this Project Thesis has been
submitted in support of an application for another degree or qualification of this of any
other university or other institute of learning. If any act of plagiarism found, we are fully
responsible for every disciplinary action taken against us depending upon the seriousness
of the proven offence, even the cancellation of our degree.
COPYRIGHT STATEMENT
Copyright in text of this thesis rests with the student author. Copies (by any
process) either in full, or of extracts, may be made only in accordance with
instructions given by the author and lodged in the Library of NUST College of
E&ME. Details may be obtained by the Librarian. This page must form part of
any such copies made. Further copies (by any process) of copies made in
accordance with such instructions may not be made without the permission (in
writing) of the author.
The ownership of any intellectual property rights which may be described in this
thesis is vested in NUST College of E&ME, subject to any prior agreement to the
contrary, and may not be made available for use by third parties without the
written permission of the College of E&ME, which will prescribe the terms and
conditions of any such agreement.
ACKNOWLEDGEMENT
First of all, we are eternally grateful to Allah Almighty who blessed us with wisdom and
courage to achieve what we had promised.
Secondly, we are thankful to our project supervisor Col. Dr. Syed Waheed Ul Haq who
gave us the initial idea about producing compressed air from speed breaker and without
his motivation and persistent help, we could not do this project. Thirdly we would like to
thank Sir Raja Amir Azeem for his suggestions and continuous guidance throughout our
project.
Next, we would like to thank the college authorities for providing us with required prerequisite. In the Last but not the least we would like to express our acknowledgement for
our parents who educated us enough well and their prayers remained with us at all the
times.
ABSTRACT
The natural resources in our country are decaying day by day. These energy crises
includes short fall of thousands of megawatts of electricity, the increasing prices of fuels
like gasoline, CNG etc. It seems that for foreseeable future, these crises would persist. So
to contribute to this national cause, we had been assigned a project to work on renewable
energy.
The aim of our project was to design an efficient energy harvester which will act like a
speed breaker and which will utilize the highway traffic for its working. An energy
harvester is a device that actually converts the vehicles mechanical energy into usable
electrical energy.
The working principle of our project is that when a vehicle will pass over it, it will move
down, by doing so, the air will be compressed by pistons. And this air will be used for
driving engine or generator directly for producing electricity. Different software's have
been used for its modeling, analysis and parametric studies i.e. Pro/E, ANSYS
Workbench 14.0 and matlab.
TABLE OF CONTENTS
Declaration and Copyright Certificate.....3
Acknowledgements.........4
Abstract...5
Table of Contents. .6
List of Figures.....10
CHAPTER 01
INTRODUCTION
1.1.
1.1.1. Overview........13
1.1.2. Solar Energy..13
1.1.3. Wind Energy..14
1.1.4. Bio-Mass.........15
1.1.5. Speed Breaker as an energy harvester16
1.2.
Aim of project17
1.3.
Motivation......18
CHAPTER 02
SPEED BREAKERS GENERAL OVERVIEW
CHAPTER 05
SOFTWARE MODELING, ANALYSIS AND FABRICATION
5.1.
Analysis....56
Design No.1..56
5.2.1.2.
5.2.1.3.
5.2.2.
Lower Plate...63
5.2.2.1.
Design No.1......63
5.2.2.2.
5.2.2.3.
Design No.3..68
5.3.
Fabrication......70
CHAPTER 06
COMPRESSOR DESIGNING
6.1. Assumptions....73
6.2. Calculations.....73
6.3. Conclusions..74
CHAPTER 07
CONTROL SYSTEM DESIGNING
7.1. Designing......75
CHAPTER 08
SELECTION OF ENGINE
8.1. Wankel engine.....79
8.1.1. Advantages...79
8.1.2. Disadvantages...80
8.2. Two Stroke Engine.....80
8.3. Four Stroke Piston Engine.81
8
8.4. Selection...81
8.5. Basic Functions of compressed air engine81
8.6. Modifications Required..82
8.6.1. Stroke-1.82
8.6.2. Stroke-2.82
8.6.3. Timing82
8.6.4. Camshaft Design...82
8.6.5. Design Concept of Camshaft...83
8.6.6. Analysis of Camshaft...83
8.6.6.1. Constraints and Pressure Application........83
8.6.7. Modal Analysis ....84
8.6.8. Static Analysis...85
8.7. Fabrication of Camshaft.87
CHAPTER 09
COMPRESSED AIR APPLICATIONS
9.1. Applications...89
CHAPTER 10
CONCLUSIONS AND RECOMMENDATIONS
10.1. Conclusions..90
10.2. Recommendations...90
REFERANCES.91
List of figures
Fig: 1.1 Common working cycle of a solar panel...14
Fig: 1.2 Windmill turbine along with the main components15
Fig: 1.3 Anaerobic compositing..15
Fig: 1.4 No of vehicles per 100,000 people....17
Fig: 1.5 Protest against the load shedding in Lahore...........18
Fig: 1.6 Protest against load shedding in Peshawar..18
Fig: 2.1 Common speed breaker.....20
Fig: 2.2 Speed Bump across the width of the road...21
Fig: 2.3 Speed Cushions across the width of the road..22
Fig: 2.4 Speed Tables......23
Fig: 3.1 Silver Grey Metallic Aluminum...25
Fig: 3.2 Mild Steel Sheets...27
Fig: 3.3 Cast iron sheets.....28
Fig: 4.1 Suspension Springs...30
Fig: 4.2 Storage cylinder....43
Fig: 5.1 Front View....49
Fig: 5.2 Side View..50
Fig: 5.3 Top View..50
Fig: 5.4 Isometric View of upper part......51
Fig: 5.5 Isometric View of piston 51
Fig: 5.6 Front View of piston ..52
Fig: 5.7 Top view of piston ..52
Fig: 5.8 Upper Assembly...53
Fig: 5.9 Front view of lower part .53
Fig: 5.10 Right view of lower part54
Fig: 5.11 Top view of lower part .....54
Fig: 5.12 Isometric view of lower part .55
10
12
Chapter 1
INTRODUCTION
With the gradual increase in the prices of fossil fuels and other traditional sources of
energy, there rises a great need for alternate sources in order to meet the energy needs for
a country. And also these fossil fuels are depleting day by day. The over view of the
energy consumption in year 2004 shows that if these resources are being consumed at the
current rates, then by 2020, more than 80% of the entire available energy resources will
be consumed particularly oil and natural gas. The combustion products produced from the
petrol, diesel etc. has caused serious global problems, which includes the ozone layer
depletion (which stops the suns UV rays from coming to earth), greenhouse effect,
environmental pollution and acid rains. These are posing great danger to our environment.
13
14
on the blades. Here in this figure, we can see that the blades are connected to the
generator via shaft and gears assembly.
1.1.4. Bio-Mass
Bio-Mass is an organic matter from wood, dead bodies and animal waste. It is also one of
the form of energy used as a source of heat for domestic purposes. The municipal waste,
manure, and agricultural by products are also included in the category of bio-mass which
can be converted into valuable fuels for vehicles and industrial applications. It is actually
a universal source of energy which can be converted in almost every form of energy as
liquid and natural gas, electricity and process heat etc. Different technologies have been
used for bio-mass conversion.
Direct Combustion
Anaerobic Digestion
Enzymatic Fermentation
16
Figure 1.4: Statistical data provided by Government of Punjab, no. of vehicles per
100,000 people
Is compact
17
1.3. Motivation
The main thing from which we get motivation for this idea of producing compressed air
from speed breaker is the current situation of Pakistan. Load shedding of electricity and
Sui-gas has crossed all the limits. Almost every day, we see there is a protest going on
against load shedding of electricity, or increase in the prices of petroleum etc. There are
some pictures shown below, from where it can easily be seen.
18
their business from our country, multinationals are moving from this country. Pakistan is
passing through the worst era of history. In order to save our country, we have to put an
effort to contribute to decrease the bad situation of Pakistan. Although this contribution is
very small that has a minor effect on the energy crises but if it worked then it can be
applied at major level to produce usable energy.
We are not alone in the world who is encountering the energy problem; many other
developing countries of the world are also facing these problems. But they have found
some means to cater for these problems. We have got this enthusiasm from other
developing nation of the world. We would be proud to do something for our country and
our people.
19
Chapter 2
SPEED BREAKERS GENERAL OVERVIEW
2.1. General Overview
Speed breaker is generally a device used to reduce the speed of the vehicle in order to
stop the road accidents. In different countries it is known with different names. For
example, in Jamaica, it is known as a sleeping policeman/a kipping cop. In British
accent, it is known as speed hump/road hump. In New Zealand accent, it is known as,
a judder bar. And Pakistani and Indian usually use to say it as Speed jump. It usually
ranges in heights between almost 3in to 4 across the whole width of the road. They are
made of different materials like recycled plastic, asphalt, metal and rubber etc.
The use of these speed breakers has been increased in the world and they can be found at
those places where there is a need to slow down the vehicles speed. The speed limit for
these speed breakers is almost 11 m/sec (40 km/h). Although they are effective in
reducing the speed of the vehicle. But they are the cause of noise pollution and also
become the cause of vehicle damage if a vehicle passes over it with high speed. Figure
2.1 shows the common speed breaker.
20
21
are used on high dense roads with some particular speed limits. Typical speed limits used
for these types of speed breakers ranges from 20 mi/hr. to 30 mi/hr. Figure 2.4 shows the
speed tables.
Types of pistons
23
Economically feasible
Applications
Safe operation so that it might not damage the lower side of the vehicle
Easy to be manufactured
2.4. Conclusion
We are not discussing the actual speed breaker or their working, nor types and uses.
These things can be found on web. Because here in our case the geometry of speed
breaker that we are using is important due to the availably of space.
Our main requirement is that our speed breaker should be compact in size and light in
weight if possible. Moreover, the cost of this whole assembly should be less. After
studying the mentioned types of speed breaker, we come to a conclusion that we cannot
use any of speed breaker from here. So we have designed our own speed breaker which
resembles a little bit with the speed tables. After doing some necessary mathematical
calculations and experiments we can say that it can fulfill our requirements.
24
Chapter 3
MATERIAL SELECTION
3.1. Introduction
There are many materials available that can be used. These materials include aluminum,
Mild steel or Low carbon steel, and Cast iron. Lets first discuss these materials and their
properties.
3.1.1. Aluminum
Aluminum is a ductile material and is found in the boron group in the periodic table. Its
color is silvery white. The symbol for this metal used is Al; having atomic number 13.
This metal is not actually soluble in water. It is found in the Earth crust in abundance and
3rd most abundant metal. Earths total weight comprises of almost 8% of this elements
solid surface. It is one of the reactive elements in the nature.
It has very good resistance to corrosion capabilities. Its alloys are mostly used in
aerospace and other transportation and building areas. As it is reactive in nature this can
be used as a catalyst in the chemical mixtures. Also it is used in explosives as ammonium
nitrate to extend the blast power.
25
26
It is a very soft material, durable, light in weight, and malleable with different
appearances range from silver to dull greyish. It cannot be soluble in alcoholic liquids.
The yielding of this metal in pure form ranges from 7MPa to 11MPa. While, its alloys
have yield strengths in range from 200 to 600Mpa. As its surface consists of very thin
layer of aluminum oxide, its corrosion resistance is very high.
In powdered form, it does not leave its silvery color. Its atoms are arranged in a face
centered cubic structure. [4]
27
Its main component is silicon which makes it grey cast iron. It has many useful
properties. When it is solidified, it expands as the graphite precipitates. This results in the
sharp casting of material. It has high thermal conductivity because of graphite present in
it. It has capability to damp the mechanical vibrations. [6]
28
3.2. Conclusion
Aluminum is softer material and also very expensive so this is not suitable for our case.
Because in our case, the material should be harder so that it can bear the load of almost
500 to 600kg and also reversal loadings.
Cast iron is brittle material as compared to mild steel and aluminum. It cannot be bended
as easily as other materials do. Because it contains high carbon contents. Which make it
very strong and brittle.
Mild steel has all properties which we needed. It can easily be bended and easy to work.
It is also not very costly and easily available. So, we have selected this material for our
project.
29
Chapter 4
DESIGNING OF MECHANICAL COMPONENTS
In our project, the components to be designed include the following:
1. Springs
2. Bolts
3. Pressure cylinder
4.1. Springs
Spring is the main component of our project. It is serving two purposes. One, this is
supporting the upper part and the second, when a load is applied on the upper part, the
upper plate and piston assembly moves down, it is then used to restore the upper
assembly to its original position. Different springs were designed and best design was
selected on the basis of our loading conditions and other general requirements.
4.1.1. Constraints
In our project, there are two constraints on the basis of which we have selected our
springs.
1. Rod on which spring is wounded
30
2. Height
Here material can also be our constraint because of its availability. We have used Chrome
silicon steel for our spring designing.
These constraints are applied to all the spring designs.
4.1.2. Material
4.1.3. Assumptions
1. Isotropic properties.
2. Select the weakest point that shows the strength of material.
3. There is no buckling.
4. Stress concentration is assumed negligible.
5. Temperature effects are negligible.
6. Gravity is constant (9.8
).
7. No humidity.
8. Perfect lubrication.
9. No crack is induced.
10. The machine element is mechanically balanced and no vibration will be induced.
Therefore, there is no additional fatigue load acting upon the part.
11. Nested round wire due to space limit.
12. No localized yielding induced.
13. Short peening is engineering decision.
14. Stiffness is consistent according to Energy Theory.
15. Set removal is zero for fatigue.
16. The induced stresses of wire bending are normal to shear loading so we ignore it
due to hot working.
31
Over a rod
32
) (
(
(
)
)
(
As this design is fulfilling our requirement, it can be our suitable design. But for the time
being, we cannot take it as our final design. First we will discuss other designs with
varied diameter.
33
Over a rod
) (
Over a rod
) (
(
(
)
)
35
)
(
As height, is our one of the constraint so we cannot go beyond 381 mm where solid
length of 13 mm diameter spring is 339.46mm.
Which is far less than we need so this is also not feasible. So we are left with spring
design # 1 having wire diameter of 10 mm.
Over a rod
36
) (
Our design depends on the availability of the desired spring from the market because
manufacturing of our own spring is very costly. From the spring designs above, it is clear
that spring design # 1 is the best option but it is not available from market so we looked
for the spring having a wire diameter nearly equal to 10 mm so we got the spring having
wire diameter of 9.525 mm which is having a factor of safety nearly equal to that of 10
mm wire diameter spring.
4.2. Bolts
Bolt is the next member after spring which is bearing load. Now, there are some design
consideration for bolts.
4.2.1. Assumptions
1. The stress concentration effects are neglected.
2. The bolt is not tighten much otherwise the washer can crack.
3. During tightening, assume not all load eventually drops at the nut head.
4.
).
9. No humidity.
37
38
The next size nearest to this calculation is 32mm = 3.2 cm for the bolt.
( )
Where
)2
Tensile-stress area
Length of threaded portion in grip
Major diameter area of fastener
Length of unthreaded portion in grip
Where
is the estimated effective stiffness of the bolt or cap screw in the clamped zone
or area.
[
Where
C= Fraction of load applied P on bolt
39
SAE Grad 1
40
Where
P= External tensile load
Factor of safety = n =5
No. of bolts used = N = 3
So, using values we get,
41
42
4.2.4. Inspection
The available bolts in market are of IBI standards. We have to use bolts of this standard.
There is a minor difference in the dimensions of the bolts used in the calculations. But all
the calculation are done for the SAE standard bolts.
The stress calculation has been done using MD SOLIDS software. There is report
generated from this software.
.
The axial stress is computed from equation
43
)(
The axial stress parallel to the longitudinal axis of the closed cylinder is
)(
The hoop and axial stresses are the in-plane principal stresses for the cylinder. The third
principal stress acts in a radial direction. On the other side of the cylinder, the (gage)
pressure is zero.
Consequently, the radial stresses in our case will be:
As the pressure pushes the inside surface. The magnitude of the radial stresses is much
smaller than the in-plane stresses, and it is often ignored. If the radial stress is considered,
a
state
of
tri-axial
stress
exists
on
the
inner
surface
of
the
cylinder,
, is the third principal stress. This non-zero principal stress affects the
magnitude of the absolute maximum shear stress.
44
)(
The maximum shear stress in the plane of the cylinder wall (in-plane shear stress) is given
by
)(
On the inside surface of a closed cylindrical pressure vessel, the absolute maximum shear
stress must account for the radial stress created directly by the pressure. The most positive
principal stress is the hoop stress,
Therefore, the absolute maximum shear stress on the inside surface of the cylinder will
be given by
(
[
)
(
)]
45
Using
)(
)(
The strain in the radial direction (caused by the Poisson effect) is given by the equation:
( )(
)(
The internal pressure creates an equal compression stress in the radial direction on the
inner surface of the cylinder (i.e.,
).
Since there are normal stresses in three direction on the inside surface of the cylinder
(longitudinal, hoop, and radial directions), the wall is under the state of tri-axial stress.
We must use Hooke's Law for tri-axial stress to compute the normal strains.
Using
)[
)]
(
46
)]
)[
)]
(
)]
.
The strain in the radial direction (caused by the Poisson effect) is given by
( )[
(
)[
)]
(
)]
.
Note that the difference between the strains on the outer and inner surfaces is relatively
small, and this difference gets smaller as the ratio of inside radius to wall thickness (r/t)
gets larger. Because of this, the effect of pressure on the inside surface of the cylinder is
sometimes neglected when computing strains in the cylinder.
Stresses on a weld:
The normal and shear stresses acting perpendicular to the specified welded joint (that is,
in the n-direction) are given as:
And
And
Respectively.
47
48
Chapter 5
SOFTWARE MODELING, ANALYSIS AND FABRICATION
After completing the designing of theoretical part, there comes the software modeling
part. As it is necessary to investigate our model in some software like Pro/E, ANSYS etc.
because these software include all the factors which we cannot include in our manual
designing like temperature effects, different material properties, different physical
properties etc. This is also because now a days, industries also use different designing
software in order to get more reliable results.
The software used for modeling of our project is Pro/E wildfire 5.0. And the analysis of it
has been done on ANSYS workbench 14.0 with module static structural.
49
50
5.1.2. Pistons
The modeling of pistons has also been done using Pro/E.
51
52
53
54
in the sleeves and compressed air can be produced. Springs are connected using
mechanisms in Pro/E assembly.
5.2. Analysis
Now, here comes the part of analysis.
Here in our case, as we cannot do the manual calculations for the upper and lower plates
so we have to do this using some designing software. We have used ANSYS workbench
14.0. There are three designs each for both the plates.
In our case, as we have selected mild steel. We can do designing on the basis of this.
Another thing is that we can use the greater length. But we cannot use the greater length
as our design is already enough large in size, so with the increase in the size, then more
space will be required for its installation. Last thing, which is now left behind is the
thickness of the both plates. All these analysis have been done on the worst case
scenarios.
5.2.1.Upper Plate
5.2.1.1. Design No.1
Thickness of the upper plate = 2mm
After applying loadings,
56
57
Factor of Safety:
As the factor of this design is very low which can be used for our case because of heavy
duty work. And the also the deformation are greater in this case.
58
59
60
Now this factor of safety is reasonable for our case as there are reversal loadings present
in it. But first we have to examine that the next design is more feasible for our project or
this one.
61
62
The results shows that this is also suitable design for our case. But as we know that the
higher the factor of safety, the higher the price of material. So keeping in all aspects, we
come to a conclusion that the best choice is the second design.
5.2.2.Lower Plate
5.2.2.1. Design No.1
Thickness of lower plate= 5mm
After applying loadings:
63
64
Although we are applying load on this plate which cannot be reached up to this extent.
But still this factor of safety is very low we cannot chose this for our project.
65
66
This can be suitable for our final design but we have to first examine the next design than
on the basis of both these results we can conclude our final result.
67
68
This can be more feasible design for our project but we cannot take this because if we
take this thickness, our project would be not be economical.
So, our suitable design would be 5mm.
69
5.3. Fabrication
Different techniques has been used for the fabrication of our project. The material used
here was already been decided in the past chapters. These techniques includes the
following:
Bending
Welding
Sand Casting
Machining
Polishing and Finishing
Hydraulic Pressing
70
71
72
Chapter 6
COMPRESSOR DESIGNING
In our case the pistons which are in sleeves and are well insulated are acting as a
compressor. The inlet to the compressor is the hole as in the case of two stroke engines.
The initial pressure of the air is atmospheric pressure. When piston passes through the
inlet hole it compresses the air to certain high pressure which then opens the check valve
and compressed air moves to the storage cylinder. The calculation of the discharge
pressure from the cylinder is calculated as follows.
6.1. Assumptions
1. This is isothermal process. There is no change of temperature as we are not
dealing with higher pressure.
2. Friction is neglected
3. Atmospheric pressure is 1 bar.
4. There isnt any loss of pressure
6.2. Calculations
Given data:
Solution:
First we have to find the compression ratio from the formula given below
Putting values
73
(
)
So
and
we get
Where
6.3. Conclusions
74
Chapter 7
CONTROL SYSTEM DESIGNING
7.1. Designing
The main parts included in our system for control system designing are:
Springs
Pistons
The springs has been discussed in detail in past chapters. So here we will discuss the
Piston which is actually acting as a damper in our case.
Damper is the part of suspension system and it functions as it has liquid in it and as we
know that liquids are incompressible moreover, dampers are used in combination with
springs and as the vehicle passes through rough roads, damper makes the motion of
spring smooth as it has liquid so liquid takes the force and keeps the vehicles smooth and
comfortable for the passengers. Here in our project as sir is being compressed in the
cylinders with the help of pistons. When force is applied on the ramp it moves down and
compresses the air but as air is compressed and a pressure is developed inside and that air
cant be further compressed so it will oppose the motion of the ramp and thus acting like
a damper.
75
)
( )
( )
Now for state space model we use the initial differential equation
Replacing
Comparing Equations
76
[ ]
[ ]
( )
( )
This is our required transfer function. Now using Matlab we have found the different
types of response plots.
Matlab Code:
For simple case:
>> m=30;
k=15500;
c=4309.87;
s = tf('s');
P = m/(s^2 + (c/m)*s + (k/m));
step(P)
stepinfo(P)
ans =
RiseTime: 0.5953
77
SettlingTime: 1.0671
SettlingMin: 0.0523
SettlingMax: 0.0581
Overshoot: 0
Undershoot: 0
Peak: 0.0581
PeakTime: 2.7996
78
Chapter 8
SELECTION OF ENGINE
We have different engine which we can modify according to our design. But first of all
we have to investigate that which engine will fulfill our requirement.
8.1.1. ADVATAGES
79
As the rotor is directly connected to the output shaft in the Wankel engine thus there is no
need of connecting rods, a crankshaft and crankshaft balancing weights that is why
Wankel engine is lighter than that of reciprocating engine of similar power output.
Vibrations produced by Wankel engine is less as discussed above so it results in smoother
power flow.
8.1.2. Disadvantages
The overall sealing of Wankel engine is worse even piston rings are not perfectly sealed
and allow for expansion. This is the main factor for decreasing the efficiency of Wankel
engine and constraining its use in the automobile industry.
engine, the specific fuel consumption is more than a 4-stroke engine which increases the
cost of its operation.
8.4. Selection
Using air as a fuel to run engine requires perfect insulation. As we all are aware of the
compressors in which a slight leakage can ruin all the efforts. First choice was Wankel
engine but we were constrained to look for other engine because of its least availability in
Pakistan market. We looked at 2-stroke engine but in this case, for an engine to work on
compressed air we have to give it a mean effective pressure on piston head, our inlet and
power stroke cant be overlapped which is necessary so it was also rejected. Next option
considered was a 4-stroke engine which met our criteria of overlapping the inlet and
power stroke so we decided to convert this 4-stroke piston engine to compressed air
engine.
We selected a C-70 engine and we will move on to understand its operations and we will
derive a system to convert it to compressed air engine.
81
As we know there will be only two strokes required for a compressed air engine to work.
Air with certain mean effective pressure will push the piston down thus giving a power
stroke and as the piston moves up, the exhaust valve will have to be opened so that the air
can get out and piston can travel in upward motion without any hurdle. The next condition
is that the intake valve must be closed while piston is coming up so that there can be
minimum forces on the piston head.
8.6.1. Stroke-1
In the first stroke, intake valve will open and compressed air will push the piston down
hence the intake stroke will also act like the power stroke.
8.6.2. Stroke-2
In this stroke, exhaust valve will open and the air which is still at higher pressure than
ambient will move out.
8.6.3. Timing
For the compressed air engine, it is obvious that both the valves must be open twice for
each revolution of crank shaft as compared to a conventional 4-stroke engine in which
valve open once every two revolutions. This obviously telling us that there is a need to
change the design of camshaft.
For two revolutions of crankshaft, camshaft will move only one revolution and valves will
open only once. Now, we want to open the valves twice during one revolution of camshaft
so we have to make mirror of each lobe at 180 degree to existing lobe means now we have
four lobes.
83
As in our case the camshaft only rotates in one plane while its translation in any direction
is restricted so we gave the camshaft the displacement constraint along X Y Z directions.
While it is constrained to rotate in XY plane. The conditions are shown in the figure
above. As we know that the only component upon which force will act are the lobes of
camshaft so we only applied pressure on the lobes. We searched for the pressure which is
acting on the camshaft lobes and applied it. After that we selected the material which is
steel in our case.
After the application of constraints, pressure and material we are now able to run the
analysis. The results are as follows.
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This is the displacement for the combined mode and its value is 2.66 and these will be
balanced by rocker reaction so our model is safe and reliable.
The deformed shape is as follows
After applying the von misses stress criteria and compared it with the yield strength of the
steel the factor of safety found to be 56.88. These analysis shows that the camshaft is safe
so we can use it in our engine.
Wood working
Sand Casting
Machining
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Chapter 9
COMPRESSED AIR APPLICATIONS
In everyday life, compressed air can be used in countless different ways. Compressed air
is widely used in industry because of its safety and reliability. Most of the companies use
compressed air at some stages of their operations. In modern industries, the
manufacturing processes often utilizes compressed air. Equipment in automotive working
shops, presses, dry clean stores depends upon reliable compressed air supply. Road
construction companies also use compressed air to power their tools. It is also used in
blowers, pneumatic tools and spraying guns. Some of these applications are mentioned
here as:.
9.1. Applications
Vehicle services
Power generation
In Plastics
In wood
In Electronics
In metals
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Chapter 10
CONCLUSIONS AND RECOMMENDATIONS
10.1. Conclusions
Our project is although a small but not the least effort towards the harvesting of energy.
Now this is the suitable time because our country is facing huge energy crises.
Our speed breaker is producing compressed air having pressure of almost 5 to 6 bar. We
have also modified Honda CD 70 bike engine as an application of compressed air. This
engine requires compressed air having pressure of almost 3 bar. Our goal was to achieve
compressed air having a pressure of 7-8 bar which we have nearly achieved. As this was a
new idea, so achieving such pressure is above our expectations. The whole assembly is
simple and easy to install. The selection of right material for the upper and lower plates
was a great deal for us. Similarly the suspension springs were not that easy to select. Thus
this project was a great increase in our practical and theoretical knowledge.
10.2. Recommendations
We have used mild steel for our project but it is too heavy and there is a risk of
rust and corrosion so we recommend that composite materials should be used
instead as it can provide same strength, it would be non-corrosive and it will be
lighter than mild steel.
We have used 4 pistons for compressing air and these pistons are connected to
upper sheet through connecting rods which are acting as point loads. In order to
avoid these point loadings we recommend the connection between the upper plate
and pistons via truss structure so that the whole weight can be distributed evenly
in the truss members.
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REFERENCES
1- http://adeelmohammad.weebly.com/1/archives/04-2013/1.html accessed on 02-072013
2- http://piaf.pk/photogallary.html accessed on 02-07-2013
3-http://pukhtunkhwatimes.blogspot.com/2009/07/protest-against-loadsheddingin.html accessed on 02-07-2013
4- http://en.wikipedia.org/wiki/Aluminium accessed on 03-07-2013
5- http://en.wikipedia.org/wiki/Mild_steel#Mild_steel accessed on 03-07-2013
6- http://en.wikipedia.org/wiki/Cast_iron accessed on 03-07-2013
7- Tasfia Rahman- Design of Efficient Energy Harvester from Ambient Vibration- Thesis
Work, April 2012
8- Andrea Pirisi, Francesco Grimaccia, Marco Mussetta, and Riccardo E. Zich- Novel
Speed Bumps Design and Optimization for Vehicles Energy Recovery in Smart Cities14 November 2012
9- Aswathaman. V- Energy Speed Breaker is Now a Source of Power- 2010 International
Conference on Biology, Environment and Chemsitry, IPCBEE vol. 1 (2011) IACSIT
Press, Singapore
10-Ashok Kumar Sharma, Omkar Trivedi, Umesh Amberiya, Vikas SharmaDevelopment of Speed Breaker device for generation of compressed air on highways in
remote areas- International Journal of Recent Reseach and Review, VOL 1, March 2012
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