Design and Fabrication of Electricity Generation from

Speed breaker

SESSION 2010-2014
PROJECT SUPERVISOR
Engr. Shehriyar Ahmed
SUBMITTED BY
Zeeshan Nawaz

UET10-ME-SCET-01

Muhammad Zeeshan

UET10-ME-SCET-25

Abubakr Saleh

UET10-ME-SCET-10

Department of Mechanical Engineering

Swedish College of Engineering & Technology

Wah Cantt
(Affiliated with University of Engineering & Technology Taxila)

In the Name of Allah, Most Gracious, Most Merciful

O my Lord, Cool My Temper.
And make this matter Easy for Me.
And Unite a Knot from My Tongue.
So, they can Understand My Speech.

AL-QURAN (20:25-28)

As partial fulfillment of the requirements for the

Bachelors Degree
In
Mechanical Engineering
This report is submitted to
The Mechanical Engineering Department

Swedish College of Engineering & Technology

Wah Cantt

____________________
Internal Examiner

_______________________
External Examiner

___________________
Head of Department
Mechanical Engineering

Department of Mechanical Engineering

Swedish College of Engineering & Technology

Wah Cantt
(Affiliated with University of Engineering & Technology Taxila)

DECLARATION

We declare that the work contained in this thesis is our own, except where explicitly stated
otherwise. In addition this work has not been submitted to obtain another degree or professional
qualification.

1. Signed: ______________________
Zeeshan Nawaz

2. Signed: _______________________
Muhammad Zeeshan

3. Signed: ________________________

Abubakr Saleh

Department of Mechanical Engineering

Swedish College of Engineering & Technology

Wah Cantt
(Affiliated with University of Engineering & Technology Taxila)

ACKNOWLEDGEMENT
First of all we thank Allah Almighty for giving us the strength and ability to complete this
project thesis.
We would like to thank our supervisor Engr. Shehriyar Ahmed for his guidance and
support through-out the course of this thesis. We would also like to thank faculty of electrical
department who helped us in electrical portion of our project. We are thankful to lathe operator
Muhammad Abid who helped a lot in fabrication process. And we are thankful to other class
fellows, teachers. Lab-operators who guided us well.
At the end special thanks to our parent for without their support and prayers it would not
have been possible.
______________________________________________________________________________

Authors

DEDICATED
With a sense of thankfulness to our
Beloved Parents
Whom parental love and selfless
Devotion to the cause of
Our well-being and sources of
Inspiration to us
But have also inculcated in us a zest
Of knowledge and learning
And a deeper sense of duty towards
Our country and fellow being
To our Teachers
From them we learnt continuously
Throughout the time we were here
And who guided and stimulated us
Throughout our educational career

ABSTRACT
An energy crisis may be referred to as an oil crisis, petroleum crisis, energy shortage, electricity
shortage, electricity crisis. So an alternative energy source is required which is cheap, no natural
input source is required to generate electricity. This project is about GENERATION OF
ELECTRICITY using SPEED BREAKERS.
In this project a mechanism to generate power by converting the potential energy generated by a
vehicle going up on a speed breaker into electricity. When the vehicle moves over the inclined
plate, it gains height resulting in increase in potential energy, which is wasted in a conventional
speed breaker. When the breaker comes down, the rack and pinion mechanism (translatory to
rotary motion converter) is fitted beneath. This in turn rotates a fly wheel at the middle of shaft
which rotates a gear at the end of the shaft and then rotation transfer to gear train (rpm
increased). The output of this gear train is coupled to a generator to convert rotational energy into
electricity. A vehicle weighing 1,000 kg going up a height of 10 cm on such speed breaker
produces approximately 0.98 kilowatt power. So one such speed-breaker on a busy highway,
where about 100 vehicles pass every minute, about one kilowatt of electricity can be produced
every single minute.

Contents

Chapter 1.................................................................................................................. 10
1.1

INTRODUCTION............................................................................................ 10

1.2 How Electric Speed breaker Works?.............................................................10

1.3 History.......................................................................................................... 10
1.4 Advantages........................................................................................................ 11
1.5 Ways to produce electricity.............................................................................. 11
1.5.1Electricity generating arm-band.......................................................................11
1.5.2 Convert work out sweat into electricity........................................................11
1.5.3 Generating Electricity While Washing Your Car.........................................12
1.5.4 Charge your iPhone while playing golf............................................................12
1.5.5 Roll Kinetic Charger to juice up your batteries.............................................13
1.6 Types of Mechanisms.......................................................................................... 14
1.6.1 ROLLER MECHANISM.................................................................................... 14
1.6.2 CRANKSHAFT MECHANISM........................................................................15
1.6.3 WORKING OF RACK-PINION MECHANISM..........................................................16
CHAPTER 2............................................................................................................... 18
LITERATURE VIEW.................................................................................................. 18
2.2 Main components of Our Project..................................................................20
2.3 Rack................................................................................................................... 20
2.4 Gears............................................................................................................... 20
2.4.1General Terminologies of Gears..................................................................20
2.5.2 Types of Gears................................................................................................. 23
1. Spur Gears..................................................................................................... 23
2. Bevel Gears.................................................................................................... 24
3. Helical Gears........................................................................................................ 24
4. Worm Gears....................................................................................................... 24

2.6 Shaft................................................................................................................... 25
2.7 Bearings.......................................................................................................... 25
2.8 Fly wheel:..................................................................................................... 25
2.9 Spring:........................................................................................................... 25
2. 10Generator...................................................................................................... 25
Chapter #3............................................................................................................... 26
DESIGN WORK....................................................................................................... 26
................................................................................................................................. 26
CHAPTER 4............................................................................................................... 30
PHYSICAL MODELING................................................................................................ 30
4.2 ASSEMBLING PHASE........................................................................................ 34
CHAPTER 5............................................................................................................... 36
FABRICATION SUMMARY........................................................................................ 36
1. Frame:.................................................................................................................. 36
5.1

PARTS OF SPEED BREAKER..............................................................................37

1. Shaft.................................................................................................................. 37
2. Bearing........................................................................................................... 38
3. FLANGE................................................................................................................. 39
5.

Flywheel:......................................................................................................... 39
6.

Metal sheet:................................................................................................. 40

7. Spring:.................................................................................................................. 40
7.

Helical Gears................................................................................................... 41
8.

9.

Rack and pinion:.......................................................................................... 42

Bolt and Nut....................................................................................................... 44

10.
11.

Bushes:........................................................................................................ 44
Generator:................................................................................................ 45

12.

L.ANGLES........................................................................................................ 46

13. Bicycle Flywheel.............................................................................................. 46

14. Electrical Accessories..................................................................................47
Chapter # 6.............................................................................................................. 60
6.1

Result and conclusion..................................................................................60

6.2 Model calculation......................................................................................... 60

6.3 Actual Calculation............................................................................................... 61
6.4 Conclusion....................................................................................................... 61
6.5 What We Achieve ?..................................................................................... 62
6.6 Future scope of this project................................................................................ 62
( EVERY SPEED BREAKER IS NOW A SOURCE OF POWER)......................................63

Speed Bumps Harvest Electricity from Moving Cars by Sarah Parsons, 09/08/09
63

List of Figure
Figure
Figure
Figure
Figure

1.................................................................................................................... 12
2.................................................................................................................... 13
3.................................................................................................................... 13
4.................................................................................................................... 14

Figure
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Figure

5.................................................................................................................... 15
6.................................................................................................................... 16
7 Rack & pinion............................................................................................. 17
8 block diagram............................................................................................. 18
9 gear............................................................................................................ 20
10.................................................................................................................. 23
11 bevel gear................................................................................................. 23
12 helical gear............................................................................................... 23
13 worm gear................................................................................................. 24
14 rack........................................................................................................... 25
15 pinion........................................................................................................ 26
16 box............................................................................................................ 26
17 breaker..................................................................................................... 26
18 dome......................................................................................................... 27
19 gear.......................................................................................................... 27
20 shaft.......................................................................................................... 28
21 motor........................................................................................................ 28
22 spring........................................................................................................ 28
23 shaft assembly.......................................................................................... 29
24 gear and box............................................................................................. 29
25 dome and box assembly...........................................................................30
26 breaker and box........................................................................................ 30
27 explode view............................................................................................. 31
28 complete view........................................................................................... 31
29 shaft.......................................................................................................... 33
30 bearing..................................................................................................... 33
31flange......................................................................................................... 34
32 flywheel.................................................................................................... 35
33metal sheet................................................................................................ 35
34 spring........................................................................................................ 36
35.................................................................................................................. 37
36.................................................................................................................. 37
37rack............................................................................................................ 38
38 bolt and nut.............................................................................................. 39
39 bushes...................................................................................................... 40
40.................................................................................................................. 40
41 generator.................................................................................................. 41
42 L-angle...................................................................................................... 41
43.................................................................................................................. 42
44 electrical accosseries................................................................................42
45 breaker..................................................................................................... 42
46 marking..................................................................................................... 43
47 cutting...................................................................................................... 43
48 holing........................................................................................................ 43

Figure
Figure
Figure
Figure
Figure
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49
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75
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77
78
79

drilling....................................................................................................... 44
hole........................................................................................................... 44
grinding.................................................................................................... 44
fixing......................................................................................................... 44
Machining................................................................................................. 45
keyway...................................................................................................... 45
keyway...................................................................................................... 45
gear making.............................................................................................. 46
Making flywheel........................................................................................ 46
working..................................................................................................... 46
Mount gear on shaft..................................................................................47
Mounting flywheel and gear......................................................................47
hinge the shaft 1....................................................................................... 47
hing the shaft 2......................................................................................... 48
mount both shaft...................................................................................... 48
making frame........................................................................................... 48
outer flywheel........................................................................................... 49
joining the rack......................................................................................... 49
rack supporter.......................................................................................... 49
bushes...................................................................................................... 50
spring assembly........................................................................................ 50
spray........................................................................................................ 50
generator.................................................................................................. 51
placing breaker......................................................................................... 51
paint the breaker...................................................................................... 51
final assembly........................................................................................... 52
paint full assembly....................................................................................52
electrical assembly................................................................................... 52
wire description........................................................................................ 53
wire coupling............................................................................................. 54
view 1....................................................................................................... 55

LIST OF TABLES
Table 1 ..................................................................................................................... 31
Table 2...................................................................................................................... 31

Table
Table
Table
Table
Table
Table
Table
Table
Table
Table
Table

3...................................................................................................................... 32
4...................................................................................................................... 32
5...................................................................................................................... 33
6...................................................................................................................... 34
7...................................................................................................................... 34
8...................................................................................................................... 36
9...................................................................................................................... 36
10.................................................................................................................... 37
11.................................................................................................................... 37
12.................................................................................................................... 39
13.................................................................................................................... 39

Chapter # 1
1.1 INTRODUCTION
1.2 How Electric Speed breaker Works?
The number of vehicles on road is increasing rapidly and if we convert some of the Potential
energy of these vehicle into the rotational motion of generator then we can produce considerable
amount of electricity, this is the main concept of this project. At present we are facing shortage of
electricity.
Electricity can be generated using speed breakers, strange, isn't it? The benefits from this idea
will be to generate electricity for the streetlights, hoardings and then for other use.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 POTENTIAL ENERGY TO
ELECTRICAL ENERGY CONVERSION Potential energy can be thought of as energy stored
within a physical system.

1.3 Why We Have Selected This Project

The current demand of electricity is 12,850 MW, while hydro power production is 2820 MW;
thermal resources produce 1800 MW; production through independent power producers (IIPs) is
5030 MW, which amounts total production of 9630 MW.
The total current shortfall despite the fact that changing weather has decreased the demand of
electricity, has reached 3250 MW, claimed National Transmission and Dispatch Company
(NTDC) authorities.
Since this mechanism is convenient to produce ample amount of energy with maximum
efficiency, we have chosen this method for our project with a very simple and effective design
for generating electricity using a rack and pinion mechanism.

1.4 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
.

1.5 Ways to produce electricity.

1.5.1Electricity generating arm-band
A mobile phone charger is powered by dance energy. The kinetic movement of a system of
weighs and magnets, which move as you groove, powers the charger. It weighs just 180 grams
and can be strapped on the dancers bicep. The energy generated while dancing can be fed into
your cell phones when the batteries run dry

1.5.2 Convert work out sweat into electricity

The energy from this power generating gym is converted from DC to AC before being
transferred into the grid. The output is considerably small; a person pedaling 30 minutes would
generate energy to run a laptop for approximately an hour.
Hence using this concept energy lost by people in gyms and aerobics daily can be efficiently
used to light up the gym as well as run few appliances like laptop, radios .etc.

Figure 1

1.5.3 Generating Electricity While Washing Your Car

Figure 2

You can recharge your electric car batteries while washing them, using nothing other than the
energy of water in the hosepipe, eventually reducing your electricity bills. The device envisioned
by Vandenbussche, POWA Water Generator, is a small turbine that is placed in between the
hosepipe. As the water rushes through the pipe it turns, the blades of the small turbine that then
generate electricity that can directly be fed into the car.

1.5.4 Charge your iPhone while playing golf

Figure 3

The gadget designed by Mac Funamizu harnesses the kinetic energy the
user generates, when the grip is swung a certain number of times, that can
be later used to charge mobile phones and other gadgets for a couple of
hours.

1.6 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

1.6.1 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.

Figure 4

DISADVANTAGES

Maintenance will be very difficult

Might cause collision

1.6.2 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.

Figure 5

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

1.6.3 WORKING OF 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.

Figure 6 Rack & pinion

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.

Figure 7 block diagram

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 leadacid battery.

ADVANTAGES
Rack-Pinion assembly gives good mounting convenience
Maximum gear losses 3 to 5%
Approximate Efficiency 95%

CHAPTER 2
LITERATURE VIEW
2.0 HISTORY
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 late1800s, Nikola Tesla pioneered the generation, transmission, and use of alternating current (AC)
electricity, which can be transmitted over much greater distances than direct current.
Electricity generation was first developed in the 1800's using Faradays dynamo generator.
Almost 200 years later we are still using the same basic principles to generate electricity, only on

a much larger scale. Now we are throwing some light on the very new and innovative concept
i.e. GENERATING ELECTRICITY FROM A SPEED BREAKER. Producing electricity from a
speed breaker is a new concept that is undergoing research.
Pakistan's installed capacity is nearly 10 per cent of China's capacity though both countries have
million plus people. There is roughly 20 percent power deficit in the peak hours. Banks are
burdened with loans to loss-making state-run electricity distribution firms and are unwilling to
lend to new projects that do not have assured fuel supply. Pakistan has nearly 5 per cent of the
world's coal reserves but lack of environmental clearances and other disputes have hindered
production.

2.1 Literary survey

1) The Burger King on U.S. Highway, Customers pull in and out all day, and at least 100,000
cars visit the drive-thru each year. And a newly installed, mechanized speed bump(video)
will both help them slow down and harvest some of that coasting energy.

Fig. 4.1 Speed Bump

The weight of a car is used to throw a lever, explains Gerard Lynch, the engineer behind the
MotionPower system developed for New Energy Technologies, a Maryland-based company.
"The instantaneous power is 2,000 watts at five miles-per-hour, but it's instantaneous which
means some form of storage will be required

2) ASWATHAMAN.V,ELECTRONICS AND COMMUNICATIONENGINEERING SONA

COLLEGE OF TECHNOLOGY, SALEM, INDIA
PRIYADHARSHINI.M, ELECTRONICS AND COMMUNICATIONENGINEERING
SONA COLLEGE OF TECHNOLOGY,SALEM, INDIA.
This paper attempts to show how energy can be tapped and used at a commonly used system- the
road speed breakers. The number of vehicles passing over the speed breaker in roads is

increasing day by day. A large amount of energy is wasted at the speed breakers through the
dissipation of heat and also through friction, every time a vehicle passes over it. There is great
possibility of tapping this energy and generating power by making the speed-breaker as a power
generation unit. The generated power can be used for the lamps, near the speed breakers. The
utilization of energy is an indication of the growth of a nation. For example, the per capita energy
consumption in USA is 9000 KWh (Kilo Watt hour) per year, whereas the consumption in India
is 1200 KWh (Kilo Watt hour). One might conclude that to be materially rich and prosperous, a
human being needs to consume more and more energy. A recent survey on the energy
consumption in India had published a pathetic report that 85,000 villages in India do
not still have electricity. Supply of power in most part of the country is poor.

2.2 Main components of Our Project

Project parts
1.
2.
3.
4.
5.
6.
7.

Rack
Spur gear
Fly wheel
Bearings
Shaft
Springs
Electric dynamo OR Generator

2.3 Rack

It is long rectangular round having teeth on one end. It is used to transmit the translational
motion into rotational motion.

2.4 Gears
A gear is a rotating machine part having cut teeth, or cogs, which mesh with another toothed part
in order to transmit torque. Two or more gears working in tandem are called a transmission and
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 a
non-rotating toothed part, called a rack, thereby producing translation instead of rotation.

2.4.1General Terminologies of Gears

Figure 8 gear

1. 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.
2. Gear, wheel
The larger of two interacting gears or a gear on its own.
3. Pinion
The smaller of two interacting gears.
4. Path of contact
Path followed by the point of contact between two meshing gear teeth.
5. 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 linethat is, the line of action is constant. indeed the case.
6. Axis
Axis of revolution of the gear; center line of the shaft.
7. Pitch point, p
Point where the line of action crosses a line joining the two gear axes.
8. 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.
9. 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.
10. Module, m
A scaling factor used in metric gears with units in millimeters whose effect is to enlarge the gear
tooth size as the module increases and reduce the size as the module decreases. Module can be
defined in the normal (mn), the transverse (mt), or the axial planes (ma) depending on the design
approach employed and the type of gear being designed. Module is typically an input value into
the gear design and is seldom calculated.
11. Operating pitch diameters
Diameters determined from the number of teeth and the center distance at which gears operate.
12. 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.
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.

13. Arc of action

Segment of a pitch circle subtended by the angle of action.
14. 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,
15. Outside diameter,
Diameter of the gear, measured from the tops of the teeth.
16. Root diameter
Diameter of the gear, measured at the base of the tooth.
17. Addendum, a
Radial distance from the pitch surface to the outermost point of the tooth
.
18. Dedendum, b
Radial

distance

from

the

depth

of

the

tooth

trough

to

the

pitch

surface.

19. Whole depth,

The distance from the top of the tooth to the root; it is equal to addendum plus dedendum or to
0working depth plus clearance.
20. Clearance
Distance between the root circle of a gear and the addendum circle of its mate.
21. Working depth
Depth of engagement of two gears, that is, the sum of their operating addendums.
22. 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.
23. Diametral pitch,
Ratio of the number of teeth to the pitch diameter.Could be measured in teeth per inch or teeth
per centimeter.
24. 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.
25. 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.
26. Interference
Contact between teeth other than at the intended parts of their surfaces.
27. Interchangeable set
A set of gears, any of which will mate properly with any other.

2.5.2 Types of Gears

1. Spur Gears

Figure 9

Spur gears or straight-cut gears are the simplest type of gear. They consist of a cylinder or disk
with the teeth projecting radially, and although they are not straight-sided in form, the edge of
each tooth is straight and aligned parallel to the axis of rotation. These gears can be meshed
together correctly only if they are fitted to parallel shafts.

2. Bevel Gears

Figure 10 bevel gear

Bevel gears are gears where the axes of the two shafts intersect and the tooth-bearing faces of
the gears themselves are conically shaped. Bevel gears are most often mounted on shafts that are
90 degrees apart, but can be designed to work at other angles as well.

3. Helical Gears

Figure 11 helical gear

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
causes the tooth shape to be a segment of a helix. Helical gears can be meshed in a parallel or
crossed orientations.

4. Worm Gears

Figure 12 worm gear

A worm gear is usually meshed with a spur gear or a helical gear, which is called the gear, wheel,
or worm wheel .Worm gears can be considered a species of helical gear, but its helix angle is
usually somewhat large (close to 90 degrees).

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

2.7 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.

2.8 Fly wheel:

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

simply it reduces the 'fluctuation' of speed.

2.9 Spring: 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.

2.9.1 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.

2. 10 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.

Chapter #3
DESIGN WORK
We have designed main components of our project.

Rack and pinion

Helical gears
Shaft
Spring

3.1 Rack And Pinion:

Module = Pitch Circle Diameter/ Number of teeth = 117/69 = 2 mm
Pitch Circle Radius(r) = 117/2 = 58.5 mm
Addendum(a) = module = 2 mm
Addendum Circle Radius (ra) = r + addendum = 58.5 + 2 = 60.5mm
Pressure angle of pinion () = 14.5 involute
Length of path of contact = KL=OK2-OL2
= (PO+LH) 2-(OPCOS ) 2
(58.5+1.6) 2-(58.5x0.93) 2

(3612-2959) = 25.55 mm

Length of arc of contact= Length of path of contact/ cos

=25.55/cos 200
=27.4mm
Minimum no.of teeth contact= Length of arc of contact/circular pitch
=27.4/( *2)
=1.8 teeth
=4 teeth = one pair
Circumference of gear

2 R= 2x 3.14x 58.5=367mm

Length of rack = 367+233=600mm

3.2 Design of Gears

Outside Diameter (Do) = 128 mm

Number of Teeth (N) = 76

Pitch Circle Diameter (D) = Do /(1+2/N) = 155/ (1+2/76) = 124.7mm

Module = D/N = 124.7/ 76 =1.64=2 mm (approx)

Pressure angle of gear () = 20

Diametral Pitch (P) = N/D = 76/124.6 =7= 0.6 mm

Addendum (a) = 1/P = 1/0.6 = 1.66=2 mm

Dedendum (b) = 1.157/P = 1.157/0.6 =1.92 mm

Tooth Thickness = 1.5708/ P = 1.5708 / 0.6=2.61mm

Whole Depth = 2.157/P = 2.157/0.6= 3.5 mm

Clearance = 0.157/ P = 0.157/0.6 = 0.26 mm

Center Distance = (N1 + N2)/ (2*P) = (76 + 19 )/ (2* 0.6) = 79.1mm

Working Depth = 2/P = 2/0.6= 3.33 mm

Addendum Circle Diameter = D + 2m =124.7 + 2(1.63) = 127.9 mm

Dedendum Circle Diameter = D 2.5m = 124.7 -2.5(1.63) = 120.63 mm

3.3 GEAR MATERIALS:

The material used for the manufacture of gears depend up on the strength and service conditions
like wear, noise etc. The gears may be manufacture from metallic or non metallic materials. The
metallic gears with cut teeth are commercially obtained by cast iron, steel and bronze. The
nonmetallic materials like wood etc cue used for reducing noise.
Cast iron widely used for gears to its good wearing properties, excellent machinabitly and easy
of producing complicated shapes by casting method.

3.4 PERMISSIBLE WORKING STRESS FOR GEAR

The permissible working stress (fw) in the lewis equation depends upon the material for which as
allowable static stress (f0) may be determined. The allowable static stresses is the stress at the
elastic limit of the material. It is also called the basic stress. In order to accounts for the dynamic
effects which becomes more severe as the pitch line velocity increases the value of working
stress is reduce.
According to the Barth formula .The permissible working stress (fw = f0 x Cv)

.Where f0

Allowable static stress

Allowable static stress for ordinary cast iron is 56
Allowable static stress for medium grade cast iron is 70
Allowable static stress for highest grade cast iron is 105

Cv

velocity factor The value's of the Cv are given as follows.

Cv

3 / 3 + V, for ordinary cut gears operating at velocities up to

12.5m/s

4.5 / 4.5 + V, for care fully cut gears operating at velocities up

to 12.5 m/s = 6/6 + V, for very accurately cut and ground
metallic gears operating at velocities up to 20 m/s

0.75 / 0.75 + V, for precession gears cut with high accuracy and
operating velocities up to 20 m/s. [0.75 11 + V] + 0.25, for non-

metallic gears. In the above expression, V is the pitch line velocity in m/s.

3.5 Tangential load on teeth

Apply lewis eqn
Wt = f x b x n x m x y
Where, f

Stress developed in teeth

Face width

module

Lewi's form factor

0.175 - (0.841) /20

0.13295

fo x C v

Where f0

Statical working stress carried by material

50 N/mm2 for ordinary grade cast iron

coefficient of velocity.

Cv=(6.1+V) / 6.1 for ordinary cut gears having peripheral velocity

Cv

below 20 m/sec.

for 20 stub involute

V = DN /60 =

3.14 X 465 X 0.124/60= 3.11m/s

Cv =(6.1+V) / 6.1=1.5
Tangential load acting on the tooth

WT = f0 x Cv b x x m x y
=105 x 1.5 x 54 x 3.14 x 2x 0.139=7424 N

3.6 Dynamic load

Formula : WD= WT +W1

Tangential load WT = P/v x cs = 981 x 0.125 / 3.11 = 39.42 N

Service factor CS = 0.125 (light shock 8-10 hours per day)
W1 =increment load due to dynamic action

21x3.11 (54x413+ 28.412)

=

-------------------------------- =144.5 N
21x 3.11 (54x413+ 28.412)

WD= WT +W1 = 39+144.5=183.5 N

3.6 Static load

WS = fe b m y

=10x5N4x3.14x2x0.1329
=471 N
WS WD so design is safe

3.7 Design of shaft

3.8 Design of Spring

CHAPTER 4
PHYSICAL MODELING
Steps:
Modeling is important phase of our project .we have completed our project using Pro _E by
PTC version 5. These are steps which we have followed are describe as under.

 According to our calculations we made all parts in pro-e part drawings.

Assembled gearing arrangements and shaft in pro-e assembling.
Assembled all parts and box.
Mesh the gears in mechanism block.
Showing the explode view and whole assembly.

1. Rack

2.Pinon

Figure 13
pinion

Figure 14 rack

3. Box

Figure 15 box

4. Breaker

Figure 16 breaker

5. Dome

Figure 17 dome

7. Shaft

6. Gear

Figure 18 gear
shaft

8. Motor

Figure 20 motor

4.2 ASSEMBLING PHASE

Step 1 :

Mount all gaer on shaft .

Figure 22 shaft assembly

Step 2:

Assemble the gears and box

Figure 19

9.Spring

Figure 21 spring

Figure 23 gear and box

Step 3:

Attach the rack with pinion

Figure 24 dome and box assembly

Step 4:

Attach the breaker with box.

Figure 25 breaker and box

Step 5:

Explode view of whole assembley

Figure 26 explode view

Step 6:

complete assembly

Figure 27 complete view

CHAPTER #5
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 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.

5.1

PARTS OF SPEED BREAKER

1. Shaft
Purpose: It is used to transmit the power and holding the gear and flywheel.
Table 1

Specification:
Picture

Length

200 mm

Dia
Material

22 mm
Mild steel

Figure 28 shaft

2. Bearing
Purpose:

Used to hold the shaft and provide balance

Table 2

Specification:

Size
Outer dia

NTN 6204
46 mm

Inner dia
Width

20 mm
14 mm

Picture:

Figure 29 bearing

3. FLANGE
Purpose: It is used to hold the bearing and it is fixed in metal sheet with the help of bolts.
Table 3

Picture

Material

Mild steel

Outer dia

56 mm

inner dia

46mm

Specification:

Figure 30flange

5. Flywheel:
Purpose: it is used to store and provide angular momentum.
Table 4

Weight

6 &10kg

Outer Dia

132mm &300mm

Inner Dia

22 mm &22mm

Thickness
Material

57 mm &22mm
Mild steel

Specification:

Picture

Figure 31 flywheel

6. Metal sheet:
Purpose:

It is used to hold the shaft and support the frame

Table 5

Picture

Length
Width
Thickness
No of sheet
Material

450
450
4mm
2
Mild steel

Specification:

Figure 32metal sheet

7. Spring:
Purpose: It is used to store and provide elasticity
Table 6

Diameter of Wire
Mean Diameter of Wire
Free length

2 mm
20mm
154mm

Pitch of spring
No of spring

57 mm
3

Material

Mild steel

Picture

Figure 33 spring

Specification:

7. Helical Gears
Purpose It is used to transmit the power from one shaft to another shaft.
Table 7

Figure 34

Addendum (a)

1.66 mm &2.09

Module
Dedendum (b)

2 &2
1.92 mm

Clearance
Tooth Thickness
Diametral Pitch (P)
Pitch dia
Outer Dia
Bore Dia

.261mm&0.284mm
3.595 &2.85mm
.6 mm &0.55mm
124.7 mm &3.39mm
128 mm &38mm
22 mm &22mm

No of teeth
Material

76 &19
Cost Iron

No of Gears

Specification:

Pictures

Figure 35

8. Rack and pinion:

It is used to convert translatory motion into rotary motion.
Table 8

Table 9

Specification:

Module

Width
Thickness

19mm
19mm

No of teeth
Material

32
Cost Iron

Teeth length
Addendum
No
of Rack (a)

155mm
2 1.66 mm

Module

Dedendum (b)

1.92 mm

Clearance

.261

Tooth Thickness

3.595

Diametral Pitch (P)

.6 mm

Pitch dia

116.62mm

Outer Dia

120 mm

Bore Dia

22 mm

No of teeth

69

Material

Cost Iron

No of Gears

Picture:

Figure 36rack

9. Bolt and Nut

Table 10

These are used to fasten two or more metal plates. These are used for temporary joint.
Outer dia
Inner dia
Thread lenght
Type
Material

Picture

Figure 37 bolt and nut

12mm
11.9
15mm
Hexagonal
Mild steel

Specification:

10. Bushes:
Purpose: It provides an interface between two parts, damping the energy transmitted through
the bushing
Table 11

Bush length
Outer diameter
Inner diameter
No of bushes
Taper bushes

2.6 mm&
2.8 mm &
2.1mm &
5
Do 32&Di 29mm

Specification :

Picture

Figure 38 bushes

Figure 39

11. Generator:
Purpose: It is used to generate electricity
Voltage
Type
Current
No of pair
No of coil
Battery

12 v
Dc
60 amp
16
2
Lead acid

Specification:

Picture:

Figure 40 generator

12. L.ANGLES
Purpose: These are used to make the frame.
Specification:

Length
Width
Thickness
Table 12

Picture:

Figure 41 L-angle

13. Bicycle Flywheel

600mm&450&380mm
30mm
0.5mm&1mm

Purpose It is assemble in pinion .it is provide free motion when rack up down
Table 13

Di
No of teeth
Size

22mm
20
0.5x0.08 inch

Specification:

Picture

Figure 42

14. Electrical Accessories

Purpose: These are used to operate and control the panel.

voltmeter

Bulb
holder

3Pn socket
Amp meter

Figure 43 electrical accosseries

15. Breaker

Figure 44 breaker

Butto

5.2

Operation and Assembly

1. Frame

Dimensions ( 460X460X600 mm)

Step 1: Marking

Figure 45 marking

Step 2: Cutting with the help of gas cutter

Figure 46 cutting

Step 3: Holing with the help of gas cutter

Figure 47 holing

Step 4: Drilling

Figure 48 drilling

Step 5: Make thread inside the hole.

Figure 49 hole

Step 6 Grinding

Figure 50 grinding

Step 6: Fasten flange and bearing with the help of nut and bolt.

Figure 51 fixing

Step 7:

Cutting with help of hacksaw.

Step 8: lathe machine Operations (turning, boring, facing, parting)

Figure 52 Machining

Step 9: Making keyway on both the shaft for mounting gear

Figure 53 keyway

Step 10: keyway

Figure 54 keyway

STEP 11: Gear making

Figure 55 gear making

STEP 12: Making flywheel.

Figure 56 Making flywheel

STEP 13: Making keyways on all gear .

Figure 57 working

STEP 14: Mounting gear on shafts 1.

Figure 58 Mount gear on shaft

STEP 15: Mounting gear on shafts 2.

Figure 59 Mounting flywheel and gear

STEP 16: Hinge the shaft 1 in the frame

Figure 60 hinge the shaft 1

STEP 17: Hinge the shaft 2 in the frame

Figure 61 hing the shaft 2

STEP 18: Complete mounting assembly

Figure 62 mount both shaft

STEP 17: Join the different angles to make frame with the help of welding

Figure 63 making frame

Step 18: mounting another flywheel outside the frame.

Figure 64 outer flywheel

Step 19: join the rack supports with the help of welding.

Figure 65 joining the rack

Step 20:

Assemble the rack support to the frame.

Figure 66 rack supporter

Step 21: Joined the bushes for spring support with the help of welding.

Figure 67 bushes

Step 22: Joined the spring.

Figure 68 spring assembly

Step 23: paint with help of spray

Figure 69 spray

Step 24: placed the Dc generator with in seat using nut and bolts.

Figure 70 generator

Step 25: placed the breakers with in seat using nut and bolts.

.
Figure 71 placing breaker

Step 26:

Cover the wooden blocks with metal sheet and paint the blocks.

Figure 72 paint the breaker

Step 27:

Attached the hump with rack and pinion mechanism

Figure 73 final assembly

Step 28:

paint the dome and other attachment.

Figure 74 paint full assembly

Step 29: Mount the bulb holders, voltmeter and inverter on transparent sheet and all
accessories .

Figure 75 electrical assembly

5.3 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

5.3.1Circuit Diagram:

Figure 76 wire description

5.3.2 Wire coupling:

Figure 77 wire coupling

5.4 FINAL MODAL

View 1

View2

Figure 78 view 1

Chapter # 6
6.1 Result and conclusion
Energy is important part to retain the industrial production rate and also the progress of any
Country. The conventional sources are reducing day by day and by the turn of century, we have
to depend upon the non-conventional sources of energy. (Non-conventional sources such as solar
energy, wind energy, biogas etc.)
We can also increase the growth of country by installing speed breaker in heavy traffic
roads and toll plaza. We can generate electricity almost continuously by using the weight of the
vehicles to produce mechanical power in the shafts by using the rack and pinion mechanism. As

this method does not require any external power source and the traffic never reduces, these speed
breakers are more reliable and have a greater life span.

6.2 Model calculation

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

6.3 Actual Calculation

Generated output voltage in one pushing force of speed breaker = 6.8v
Current in the circuit in one pushing force of speed breaker = 0.30 amps
As per ohms law
Power developed for one push= V*I = 6.8 *0.31
p= 2.1 w
Power developed for one hour

= 60 * 2.41 = 144.6 watts

Power developed for one day

= 24 * 146.4 = 3.47 kw

Power developed for one month = 30 * 3513.1 = 104.118 kw

Power developed for one year

12 * 105.408 = 1249.3 kw

6.4 Conclusion
o For 100 bikes in a day Power generated = 2.1 * 100 = 210.1 watts
o Percentage Error = (2.45 2.1)/ 2.1 * 100 = 16.2 %
o We can store the electricity produce from speed breaker in battery and then
we can use it according to desire.

6.5 What We Achieve ?

Our Actual task is to produce 12 volts which is our basically splendid first
achievement with the help of speed breaker .
Our extra work is to produce 220 volts with the help of inverter which is basically
our best achievement.

6.6 Future scope of this project

Future work would consist of a redesign of this model to see exactly how much data we may
be missing with the assumption that we made with low price, weight and capacity. Despite all the
assumptions, we still have realized that this product can be very marketable and that the demand
is extremely large which means this is a viable design that will yield a high return on an
investment.
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.

Various government departments can take up an initiative to implement these power
humps on a large scale.
These can be mainly used at toll booths , approaching traffic signals , highways where
vehicles move 24 x 7 etc
This has a huge scope everywhere provides the resources are channelled well.

Chapter # 7
References
( EVERY SPEED BREAKER IS NOW A SOURCE OF
POWER)

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 0976-7916
JERS/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