DESIGN AND FABRICATION OF

POWER GENERATION FROM SPEED

BREAKERS

A PROJECT REPORT

Submitted by

G.GOWTHAM (730314114017)

G.GUNASEKAR (730314114019)

D.KUMARESAN (730314114032)

M.ARVINTH (730314114301)

in partial fulfillment for the award of the degree

of

BACHELOR OF ENGINEERING

IN

MECHANICAL ENGINEERING

ERODE BUILDER EDUCATIONAL TRUSTS

GROUP OF INSTITUTIONS, KANGAYAM 638 108

ANNA UNIVERSITY: CHENNAI 600 025

APRIL 2017

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 ANNA UNIVERSITY: CHENNAI 600 025

BONAFIDE CERTIFICATE

Certified that this project report DESIGN AND FABRICATION OF

POWER GENERATION FROM SPEED BREAKERS is a bonafide work
of "G.GOWTHAM(730314114017),G.GUNASEKAR(730314114019),
D.KUMARESAN(730314114033),M.ARVINTH(730314114301) that carried
out the project work under my supervision.

Dr. V.P.VENKATARAMANA MURTHY M.MOHAN RAJU

PROFESSOR & HEAD SUPERVISOR

Department of Mechanical Engineering, Assistant Professor

Department of Mechanical
EBET Group of Institutions,
Engineering,
Kangayam-638108.
EBET Group of Institutions,
Kangayam-638108.

Submitted for the Anna University Viva Voce held on .

Internal Examiner External Examiner

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 ACKNOWLEDGEMENT

We thank our beloved correspondent Mr. K. R. DHANASEKAR B.E.,

and all the member of Erode Builder Educational Trusts Group of Institutions
at this high time for providing us with plethora of facilities to complete the
project successfully.

We deem it a very great privilege to express our profound thanks to our

beloved Director Dr. P. GOVINDASAMY, M.E., Ph.D., who has been a
bastion of moral strength and a source of incessant encouragement to us.

We express our sincere thanks to Dr. V.P.VENKATRAMANA MURTHY

M.Tech., Ph.D., Head of the Department, Mechanical Engineering, for his
valuable guidance and suggestions.

We express our sincere thanks to our beloved project coordinator

Mr. D. PALANISAMY M.E., for his valuable guidance and suggestions.

We take immense pleasure to express our heartfelt thanks to our beloved

project supervisor Mr. M.MOHAN RAJU M.E.,for his valuable guidance and
suggestions and constant support provided through the course of our project.

We also thank all our teaching faculty members and non-teaching staff
members of Mechanical Engineering Department and all our fellow students
who stood with us to do our project work successfully. We also extend warm
thanks to our beloved parents.

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 ABSTRACT

In this model we show that how we can generate a voltage from the busy
traffic. Conversion of the mechanical energy into electrical energy is widely
used concept.Its a mechanism to generate power by converting the potential
energy generated by a vehicle going up on a speed breaker into rotational
energy.We have used that simple concept to the project. We connect one
mechanical rod with the dynamo and fit this rod on the surface of the road.

When any vehicle moves from this roller then due to friction, vehicle Rotate the
rod or roller and roller then move the dynamo. When dynamo move then it
generates a voltage and this voltage now connects to the bulbs.

In actual practice with the help of this voltage we will charge the battery and
then we use this voltage to light the small bulb.If we install this unit to the any
small flyover then with the help of this voltage we generate a small voltage, and
with the help of this voltage we light the bulb. The second part of that project is
an efficient use of energy by using simple electronics. We always see that road
light continuously glow whether vehicle on path or not. We have introduced a
concept to avoid a waste of light. We have used two sensors between some
distances. When vehicle pass through first sensor it sends the signal to the
microcontroller that the vehicle is passing along that particular distance then
light will glow for that particular time and when vehicle goes out from the
second sensor.Then the second sensor sends a signal to a microcontroller that
vehicle has been passed through that particular path then light gets off
automatically.

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 S.NO. CONTENT P.NO

1 INTRODUCTION 6

1.1 General Principle 6

1.2 Possible different mechanisms 7
2 DESCRIPTION OF 8
EQUIPMENT

2.1 Main Parts of Electro Magnetic 8

Brake
2.2 Rack & Pinion Setup 8
2.3 Helical Springs 9

2.4 An Electric Generator Or Motor 10

3 FABRICATION 12
3.1 Construction 12

3.2 Working principle 12

3.3 General Principle and 14
Advantage Power Generation
from Speed
4.1 Advantages 16

4.2 Application 16
4.3 Cost Estimation 16
CONCLUSION 18

TABLE OF CONTENTS

CHAPTER 1
1 INTRODUCTION
In the present scenario power becomes the major need for human life .The

availability and its per capita consumptions are regarded as the index of

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national standard of living in the present day civilization. Energy is an
important input in all the sectors of any countries economy. Energy crisis is due
to two reasons, firstly the population of the world has been increased rapidly
and secondly standard of living of human beings has increased. India is the
country, which majorly suffers with lack of sufficient power generation. The
availability of regular conventional fossil fuels will be the main sources for
power generation, but there is a fear that they will get exhausted eventually by
the next few decades. Therefore, we have to investigate some approximate,
alternative, new sources for the power generation, which is not depleted by the
very few years.

Another major problem, which is becoming the exiting topic for today is the
pollution. It suffers all the living organisms of all kinds as on the land, in aqua
and in air. Power stations and automobiles are the major pollution producing
places.

Therefore, we have to investigate other types of renewable sources, which

produce electricity without using any commercial fossil fuels, which is not
producing renewable energy such as solar wind), OTEC (ocean thermal energy
conversions) etcfor power generation. The latest technology which is used to
generate the power by suchrenewable energy

1.1GENERAL PRINCIPLE

While moving, the vehicles possess some kinetic energy 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 is compressed and the

6
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. A flywheel is mounted on the shaft whose
function is to regulate the fluctuation in the energy and to make the energy
uniform. So that the shafts will rotate with certain R.P.M. these shafts are
connected through a belt drive to the dynamos, which converts the mechanical
energy into electrical energy. The conversion will be proportional to traffic
density. Whenever an armature rotates between the magnetic fields of south and
north poles, an E.M.F is induced in it. So, for inducing the E.M.F.armature coil
has to rotate, for rotating this armature it is connected to a long shaft. By
rotating same e.m.f is induced, for this rotation kinetic energy of moving
vehicles is utilized. The power is generated in both the directions; to convert
this power into one way, a special component is used called zener diode for
continuous supply. All this mechanism can be housed under the dome, like
speed breaker, which is called HUMP. The electrical output can be improved by
arranging these POWER HUMPS in series.

1.2 POSSIBLE USING DIFFERENT MECHANISMS :-

i) Spring coil mechanism

ii) Rack- Pinion mechanism

iii)Crank-shaft mechanism

iv)Roller mechanism

CHAPTER 2

DESCRIPTION OF EQUIPMENT

2.1 MAIN PARTS OF POWER GENERATION SETUP:

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 1. Rack & Pinion

2. sproket

3. Gear & shaft

4. PMDC motor or Generator

5. Helical coil spring

2.2 RACK & PINION SETUP

Speed breaker POWER GENERATOR Converters basically new concept

of non-conventional energy generation. It is electro-mechanical energy
generating machine. This machine converts reciprocating motion in to rotary
motion. The rotational power is stored in flywheel & flywheel rotates dynamo,
which generates electricity. Here first important point is how we get
reciprocating motion, which is prime input in the system. For that we use
weight of Moving vehicle on the Speed breaker. We put our machine underneath
the Sped breaker installing different units. All the units are connected to the
Common shaft using chain and sprocket drive. The head of rack is brought up to
level beneath the speed breaker surface. When vehicle moves on the speed
breaker, the rack it will be pushed down. The rack is attached with free wheel
type pinion that rotates in one direction only. The rack & pinion arrangement
convert reciprocating motion in to rotary motion.

This rotary motion is further magnified using reciprocating motion in to rotary

motion-belt & pulley drive. The output of pulley is attached with flywheel
which stores kinetic energy and transfer to dynamo which generate electricity
with zero cost. A "generator" and "motor" is essentially the same thing: what
you call it depends on whether electricity is going into the unit or coming out of
it. A generator produces electricity. In a generator, something causes the shaft
and armature to spin. This generated power is used for various application
required by different user.

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2.3 HELICAL SPRINGS

A spring is an elastic object used to store mechanical energy. Springs are

usually made out of spring steel. There are a large number of spring designs; in
everyday usage the term often refers to coil springs.

When a spring is compressed or stretched from its resting position, it exerts an

opposing force approximately proportional to its change in length (this
approximation breaks down for larger deflections). The rate or spring constant
of a spring is the change in the force it exerts, divided by the change in
deflection of the spring. That is, it is the gradient of the force versus deflection
curve. An extension or compression spring's rate is expressed in units of force
divided by distance, for example lbf/in or N/m. A torsion spring is a spring that
works by twisting; when it is twisted about its axis by an angle, it produces a
torque proportional to the angle. A torsion spring's rate is in units of torque
divided by angle, such as Nm/rad. The inverse of spring rate is compliance, that
is: if a spring has a rate of 10 N/mm, it has a compliance of 0.1 mm. The
stiffness (or rate) of springs in parallel is additive, as is the compliance of
springs in series.

Springs are made from a variety of elastic materials, the most common being
spring steel. Small springs can be wound from pre-hardened stock, while larger
ones are made from annealed steel and hardened after fabrication. Some non-
ferrous metals are also used including phosphor bronze and titanium for parts
requiring corrosion resistance and beryllium copper for springs carrying
electrical current (because of its low electrical resistance).

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2.4 AN ELECTRIC GENERATOR OR MOTOR

An electric motor is an electrical machine that converts electrical energy into

mechanical energy. The reverse of this is the conversion of mechanical energy
into electrical energy and is done by an electric generator.

In normal motoring mode, most electric motors operate through the interaction
between an electric motor's magnetic field and winding currents to generate
force within the motor. In certain applications, such as in the transportation
industry with traction motors, electric motors can operate in both motoring and
generating or braking modes to also produce electrical energy from mechanical
energy.

Found in applications as diverse as industrial fans, blowers and pumps,

machine tools, household appliances, power tools, and disk drives, electric
motors can be powered by direct current (DC) sources, such as from batteries,
motor vehicles or rectifiers, or by alternating current (AC) sources, such as from
the power grid, inverters or generators. Small motors may be found in electric
watches. General-purpose motors with highly standardized dimensions and
characteristics provide convenient mechanical power for industrial use. The
largest of electric motors are used for ship propulsion, pipeline compression and
pumped-storage applications with ratings reaching 100 megawatts. Electric
motors may be classified by electric power source type, internal construction,
application, type of motion output, and so on.

Electric motors are used to produce linear or rotary force (torque), and should
be distinguished from devices such as magnetic solenoids and loudspeakers that

10
convert electricity into motion but do not generate usable mechanical powers,
which are respectively referred to as actuators and transducers

CHAPTER 3

FABRICATION

3.1 Construction of Housing Mechanism

A dome is mounted on four springs and in the bottom, a rack is clamped.

11
The rack consists contact teeth on both the faces. It is connected to two gear
wheels to rotate the gear wheels only in one direction. We have inserted a free
wheel in each gear. The free wheel and the gear assembly are mounted centrally.
The flywheel is also mounted on the same shaft and the shaft is simply
supported at the both ends by means of ball bearings. Now a dynamo is
connected to each shaft by belt drive. The output terminal of dynamo is
connected to an electrical storing device. The total assembly is arranged in
concrete pit.

3.2 Working principle

While moving, the vehicles possess some kinetic energy 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 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. A flywheel is mounted on the shaft whose function is to
regulate the fluctuation in the energy and to make the energy uniform. So that
the shafts will rotate with certain R.P.M. these shafts are connected through a
belt drive to the dynamos, which converts the mechanical energy into electrical
energy.

The conversion will be proportional to traffic density. Whenever an

12
armature rotates between the magnetic fields of south and north poles, an E.M.F
(electro motive force) is induced in it. So, for inducing the E.M.F armature coil
has to rotate, for rotating this armature it is connected to a long shaft. Byrotating
same e.m.f, is induced, for this rotation kinetic energy of moving vehicles is
utilized. The power is generated in both the directions; to convert this power
into one way a special component is used called zenor diode for continuous
supply. All this mechanism can be housed under the dome, like speed breaker,
which is called HUMP. 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

Fig .3.2

3.3General Principle and Advantage of Power Generation from Speed

Breakers

Whenever an armature rotates between the magnetic fields of south and north
poles, an E.M.F is induced in it. So, for inducing the E.M.F.armature coil has to
rotate, for rotating this armature it is connected to a long shaft. By rotating same

13
e.m.f is induced, for this rotation kinetic energy of moving vehicles is utilized.
The power is generated in both the directions; to convert this power into one
way, a special component is used called zener diode for continuous supply. All
this mechanism can be housed under the dome, like speed breaker, which is
called HUMP. 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

3.4 Working Principle of Power Generation

The working principle of the electric retarder is based on the creation of

eddy currents within a metal disc rotating between two electromagnets, which
sets up a force opposing the rotation of the disc. If the electromagnet is not
energized, the rotation of the disc is free and accelerates uniformly under the
action of the weight to which its shaft is connected. When the electromagnet is
energized, the rotation of the disc is retarded and the energy absorbed appears as
heating of the disc. If the current exciting the electromagnet is varied by a
rheostat, the braking torque varies in direct proportion to the value of the
current. It was the Frenchman Raoul Sarazin who made the first vehicle
application of eddy current brakes. The development of this invention began
when the French company Telma, associated with Raoul Sarazin, developed and
marketed several generations of electric brakes based on the functioning
principles described above . A typical retarder consists of stator and rotor. The
stator holds 16 induction coils, energized separately in groups of four. The coils
are made up of varnished aluminum wire mounded in epoxy resin. . The rotor is
made up of two discs, which provide the braking force. When subject to the
electromagnetic influence when the coils are excited. Careful design of the fins,
which are integral to the disc, permit independent cooling of the arrangement.

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 CHATPER 4

4.1 Advantages

1. Quick operation.

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 2. Low maintenance requirement.
3. Less noise.
4. Simple in design.
5. High degree of safety.
6. It reduces the manual effort.
7. And flowing of current is very fast.
8. It is reasonable as compare with other generation systems

4.2 Application

1. Used in power generations in small scale producion

2. No obstructions to traffic
3. Noise less activity enrollment
4. Low budget all scale manufacturing side productions can be carried on

4.3 Cost Estimation

TABLE 4.1 Cost Estimation

S. No DESCRIPTION QTY MATERIAL AMOUNT

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 (RS)
1 Helical springs 2 - 600
(High tension)
2 Motor 1 - 300
3 Rack & Pinion 1 Mild Steel 200
4 Wooden setup 1 - 500
5 Gear setup 1 Mild Steel 100
Total 1700/-

Summary:

we have to investigate other types of renewable sources, which produce

electricity without using any commercial fossil fuels, which is not producing
renewable energy such as solar wind), OTEC (ocean thermal energy
conversions) etcfor power generation. The latest technology which is used to
generate the power by suchrenewable energy

CHAPTER 5

CONCLUSION

It can be implemented at metropolitan cities. So that more

electric power will be produced. Arrangement of whole setup is
easier. The stored electricity could satisfy the daily requirement of
electric power.

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 Suitable at parking of multiplexes, malls, toll booths, signals,
etc. Uses: Charging batteries and using them to light up the streets,
etc. Such speed breakers can be designed for heavy vehicles, thus
increasing input torque and ultimately output of generator.More
suitable and compact mechanisms to enhance efficiency.

REFERENCE

1.Design of Transmissions System-S. Md. Jalaludeen 2013, Anuradha

Publications Pvt Ltd.

2. Strength of Materials -R.S. Khurmi, 2010,Chand & company Ltd.

3. Manufacturing Technology -P.N. Rao, Vol II, 2009, Mcgrew hill Pvt Ltd.

4. Design of machine elements- R.S. Khurmi, 2011,Mcgrew hill Pvt Ltd.

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