Design, Modelling, and Test of a Speed Bump

Energy Harvester using Slider Crank mechanism

ABSTRACT

Man in his lifetime, uses energy in one form or the other. In fact whatever happens in
nature, results, out of the conversion of energy in one form or the other. The blowing of the
wind, the formation of the clouds and the flow of water are a few examples that stand
testimony to this fact. The extensive usage of energy has resulted in an energy crisis, and there
is a need to develop methods of optimal utilization, which will not only ease the crisis but also
preserve the environment. Energy conservation is the cheapest new source of energy. This
project attempts to show how energy can be tapped and used at a commonly used system, the
generation of electricity through the speed breaker mechanism. Generation of electricity
through the speed breaker mechanism is one of the most recent power generation concepts.
This device converts the kinetic energy of the vehicles into electric energy by installing movable
speed breaker on the road, it takes the stroke motion of the vehicles and converts it to the
rotary motion by crank shaft mechanism and it generates the electricity. This project also
explains clearly, the working principle of the designed system, its practical implementation, and
its advantages. Design of each component has been carried out using standard procedures, and
the components have been fabricated and assembled. A similar model of the system has been
modeled using solid works 2017 . Practical testing of the system has been done with different
loads at different speeds. The utilization of energy is an indication of the growth of a nation.
One might conclude that to be materially rich and prosperous, a human being needs to
consume more and more energy. And this project is best source of energy that we get in day to
day life.
 INTRODUCTION

Electricity is one of the greatest wonder of science , it is the most important

revolutionary creation in this world of ours . It has practically revolutionized the world . The
gradual but excessive use of electricity has come to bring about a stupendous changes in
industry. With it out modern gigantic tools are worked . There is not a single phase of human
life that is not indebted to electricity for its progress . The modern age has , therefore , been
truly called the “age of electricity “.

For reduction of carbon dioxide emission, renewable energies are considered as proper
alternative energy. Renewable energies mainly refer to the wind, solar, biomass and marine
currents which are less harmful to environment, attracting a wide attention of researchers in
design and development of renewable energy conversion systems. Although improvement of
renewable energy converters is in a fast rate, the systems to extract the wasted energy in
conventional energy conversion systems are not developed as much as its technologies. In
many systems and processes, dissipation of energy is inevitable whatever renewable or
conventional energy was used. For instance, as a car passes over a speed-breaker, most of car
kinetic energy will be wasted as heat in it. On other hand, to ensure the security of the
populated areas of streets, the speed-breakers are required, whatever we used electrical cars
or the cars consuming gasoil. There are numerous similar cases which such vast energies are
wasting. Like an elevator during going down, a car during going down on a sloppy street, where
regardless the used type of energy or efficiency of systems energy is systematically wasting. It is
mainly due to condition that the systems are operation in it.

In this project, we focus on the fixed speed-breaker at the streets since a high amount of
vehicles kinetic energy is wasting there. There are thousands of crowed cities with enormous
flow of vehicles offers high amount of energy can be considered as near to urban resource of
energy. Also, extraction of such energy allows eliminating of transmission system between the
remote areas and urban area for lightings purposes. There is a little literature about extraction
of kinetic energy from flow of vehicle in the streets. There is so little and invalid literatures in
generation of electricity by speed breakers that but the most common approaches can be seen
in these proposed systems, mostly small radial flux generators with ineffective topologies have
been employed. Therefore it is necessary to design a suitable and efficient topology for design
of an energy conversion system for extraction of kinetic energy of vehicles. This paper presents
a novel speed-breaker generator (SBG) for extraction of kinetic energy of vehicle flow in the
street. This device converts the kinetic energy of the vehicles into electric energy. This is done
by moving plate installed on the road, this plate take the stroke motion of the vehicles and
convert it to the rotary motion by crank mechanism and it generates the electricity. The energy
crisis is a great bottleneck in the supply of energy resources to an economy. The studies to sort
out the energy crisis led to the idea of generating power using speed breaker. Firstly South
African electrical crisis has made them implemented this method to light up small villages of the
highway. The idea of basic physics to convert the kinetic energy into electrical energy that gone
wasted when the vehicle run over the speed break explains clearly, the working principle of the
designed system, its practical implementation, and its advantages. Design of each component
has been carried out using standard procedures, and the components have been fabricated and
assembled. A similar model of the system has been modeled using Pro-E. Practical testing of the
system has been done with different loads at different speeds. Taking the various criteria that
determine the power generation, graphs have been plotted. The utilization of energy is an
indication of the growth of a nation. One might conclude that to be materially rich and
prosperous, a human being needs to consume more and more energy, were given some
advantages which are: economical and easy to install, nonpolluting, Maintenance cost is low,
Installation cost is low and also solve some of the electricity problems of the world. The
electricity produced by this system can be used to drive an electric motor or for any other
purpose. Their work can be implemented on road and can be used to lighten the street lamps.
In future it can be used to charge car batteries also explains vehicular traffic in big cities is
more, causing a problem to human being. It has advantage that it does not utilize any external
source. Now the time has come to put forte these types of innovative ideas, and researches
should be done to upgrade their implication. It can be implemented at metropolitan cities. So
that more electric power is produced. Arrangement of whole setup is easier. The stored
electricity could satisfy the daily requirement of electric power. Since the arrangement is easier
but power transmission is not as costly as its setup. Hence power can easily be transmitted. This
methods have many advantages such as Power generation does not require any fuel input,
Running cost is very less, This is a non-conventional form of energy and therefore very useful in
the present scenario of energy crisis. As coin has two faces in the same way there are also some
disadvantages such as Mechanical moving parts is high and therefore there are very large
frictional losses and therefore require more maintenance, Initial cost of this arrangement is
very high. The overall efficiency is quite low as compared to other techniques.
TYPES OF MECHANISMS

There are different types of mechanism used for generating electricity using speed breaker.

A) Roller Mechanism

In this set up, an iron roller is fixed on a wooden ramp on which vehicle can pass due to which
roller rotates in the direction of the vehicles passing over it. The roller is linked with the shaft of
DC motor (used as a generator) through a chain and sprocket arrangement. Now as vehicle
passes over it; the roller rotates the shaft of the DC motor thus producing electricity. Hence DC
power is produce through the roller mechanism which can be stored in the battery and used for
future use.

The advantage of this mechanism is that electricity can be relatively produced in a simple
manner without polluting the environment. But strength and losses are the limitations of this
method which is to be considered.
B) Rack and Pinion Mechanism

After roller mechanism, there was a major improvement in speed breaker generation unit. The
improvement was using rack and pinion mechanism in which the reciprocating motion of the
speed-breaker is converted into rotary motion. In this mechanism, the top part of the rack is
connected to the speed breaker and the lower part is linked with pinion. As the vehicle passes
over the speed breaker the rack moves in the downward direction which in turn rotates the
pinion in clockwise direction. The axis of the pinion is coupled with the sprocket arrangement
on the shafts. The sprocket arrangement is made of two sprockets. One of larger size and the
other of smaller size. Both the sprockets are connected by means of a chain which serves in
transmitting power from the larger sprocket to the smaller sprocket. As the power is
transmitted from the larger sprocket to the smaller sprocket, the speed that is available at the
larger sprocket is relatively multiplied at the rotation of the smaller sprocket. As the smaller
sprocket rotates the shaft rotates which in turn rotates the shaft of DC motor through gear
assembly.
Also a flywheel is connected on the shaft of the smaller sprocket so as to get continuous
rotation of the shaft and thus the generator. Thus, electricity is produced when pinion is rotates
in clockwise direction but what when the rack moves in upward direction.

Therefore the pinion will rotate in anticlockwise direction and cancel the movement of
clockwise direction thus decreasing the efficiency of the overall system. Hence due to this
major drawback even rack and pinion mechanism has its own limitations.

C) Air piston mechanism

Various approaches were made to generate power through speed breakers but in some way
every approach had its own limitations. Air piston mechanism is a different kind of approach
with high efficiency as compare to previous mechanisms. In this, when the vehicle (load) passes
over the curved shape metal sheet i.e. dome, it goes down due to the load of vehicle.

This assembly pushes down to the spring. This curved dome is connected with the piston via
connecting rod. This quick action (movement of piston downward) compresses air in the
compressor cylinder which escapes out (exhaust stroke) from the delivery valve and it stored in
the air cylinder (tank). When the vehicle goes away from the speed breaker, the dome along
with piston moves up quickly due to which the action of spring allows air intake into the
compressor cylinder (suction stroke). These steps are repeated with the successive passing of
vehicles. The frequent up and down movement of air compressor piston (attached with speed
breaker dome) completes the intake and exhaust strokes of the air compressor repeatedly thus
rotating the shaft of the generator.

Therefore, these repeated cycles will be possible with busy roads will store a good amount of
pressurized air in the air cylinder that can be further utilized for useful purposes. Hence power
is generated with maximum efficiency. But this set up is not beneficial from economical point of
view.

E) 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.

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 is 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 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. This
generated power can be amplified and stored by using different electrical devices.
Why we have selected this project ?
The current demand of electricity is 12850MW , while hydropower production is 2820M,
thermal resources produce 1800MW , production through independent power producers
(IIPs) is 5030MW which amount total production of 9630MW .

The total current shortfall despite the fact that changing weather has decreased the demand
of electricity ,has reached 3250MW, claimed national transmission and dispatch company
(NTDC) authorities.

Since the mechanism is convenient to produce ample amount of energy with maximum
efficiency ,we have chosen this method for our project with a simple and effective design for
generating electricity using a crankshaft mechanism.

BACKGROUND AND LITERATURE SURVEY

In today’s world, we want to have an environment where driving is more fun, intelligent,
sustained and smart. From the age of electrical based traffic lighting to the smart traffic lighting
system [1]- [2], humans are experience an unprecedented level of technological advancements
in the field of transportation and it is also an attempts to reducing the carbon foot print [3].
Intelligent Transportation System (ITS) is the category under which lot of researchers around
the world are attempting to make the transportation more reliable, intelligent, and smart[4]-
[5]. A significant research has been done, for example, on the intelligent traffic lighting. In a
research, the author, Shilpa S. Chavan, suggests a microcontroller/microprocessor based
intelligent traffic controls lights[6]. It serves a phenomenal solution to the traffic problems
associated in a city.

On the other hand, smart road concept is a new technology that combined the
transportation with artificial intelligence. For example, the use of video camera for incident
detection on roads[7]. Another breakthrough research suggesting the smart road and smart car
concept is done by J.Malik and his co-authors where they applied computer vision for intelligent
vehicle highway system[8]. They use the computer vision for the traffic surveillance, traffic
detection etc..

Vehicle tracking system as suggested by J. Malik and his co-authors under the smart
road concept [8]
 Another research done by Maria Jokela etc. suggests an optical method of detecting the
condition of the roads[9]. This is also used for detecting animals on the roads for preventing
mishaps. They use an INR camera and thermal imaging system for this purpose. In one of the
researches done by Marcin Karpi´ nski, Aline Senart and Vinny Cahill, smartly proposes a
wireless sensor network on road, or, as they called it, “cat’s eye” [10]. This is precisely one of
the areas of application of speed bump energy harvester where it can contribute to the ITS and
smart roads concept.

For all these purposes, we require an immense network of various on road sensors,
wireless technology, and a robust method of powering these electronic devices. A step towards
the intelligent transportation system and smart road concept, require electrical energy and it is
really important to understand the limitations and constraints of the conventional sources of
energy generation. Our aim is to make the ITS more independent in real sense. Another matter
of concern is how we are going to provide electrical power to keep it working independently.

As we know that that electrical energy, in today’s world, has a vital role in every human
being’s life. We simply can’t imagine a world without it. From large scale to Nano –scale
electricity, we are imbibed in the ways of producing more and more energy out of everything
that a man can think of because every single human being on this planet deserves his share of
electricity. It was projected by the international energy outlook (IEO), in 2013, that the energy
consumption of the world will grow by 56% by 2040, of which, most will be produced by liquid
sources and coal [11]. Figure 1-1(a) shows the trend of the electricity production by fuel type.
With an increase in the energy consumption, we are making the humans life better and more
productive. But, there is a darker side to it. It is a known fact that we are consuming our fossil
fuels in order to scale up and provide electricity to masses. Climate change is real and is
happening right now [12]–[15].

A lot of this climate change problem is associated with the way we are producing the
electricity. It is estimated that, in 2014, most of the electrical energy produced in the US was from
fossil fuel, such as coal, which accounted for 39% share. Figure 1-1(b) shows the US
energyproduction by fuel type[16]. Whereas, renewable sources such as hydro power, thermal,
nuclear, and other similar forms accounted for 13% and nuclear energy with 20% share in the
US in 2014
[17]. It is even larger in the developing big countries like India and China which produce 60%
and 75%, respectively, of their total energy consumption via coal [18]–[20]. We are heavily
consuming our natural resources in order to produce more and more electrical power and it is
an apprehension that, in the near future, we will run out of the natural resources[9]- [10]. Thus,
it has become vital to realize that we need to curb down our dependence on the natural
sources for the electricity generation since it is going to impact our electricity market from
region to region in different ways, not to mention, badly [23].

(a)

(b)

(a) Projections of the world energy consumption by IEO 2013. (b) US 2014 Electricity
generation by type
 In order to do so, it becomes necessary to have a paradigm shift towards the non-
conventional modes of electricity generation. A lot of researchers, scientists, and engineers
around the world are working towards the exploration of such methods which impose a
minimum damage to our environment and, at the same time, give us clean energy. Some of the
examples of such methods are wind power, gas turbine, and, most widely known, solar power
which was produced less than 1% of the of the total need in 2014 [17]. There are many forms
non-conventional and alternate ways of energy generation which we can and now have started
trapping in order to full fill the gap for our need and to reduce the carbon footprint in the
world.

Such a source of energy harvesting, which now can be synthesized, is through vehicles. With
the increase in the number of vehicles on road, there is immense potential in trapping their
potential and kinetic energy which can serve the purpose of small scale electrical power generation
enough to make the transportation more intelligent and independent. This is called energy
harvesting from running vehicle. In 2015, there were estimated 257.9 million passenger vehicles in
United States[24] which can be an immense source of energy harvesting, thus, saving millions and
billions of dollars in energy sector. On board/vehicle energy harvesting is coming to light these days.
With regenerative shock absorbers[25] to MMR based shock absorbers[26]–[31], this areais proving
to be a promising field. Hence, a technique that can used to harvest energy outside the vehicle
but using the vehicles dynamics, sounds a very interesting thought.

Research Objectives
The primary objectives of this research are to;

o Provide a platform for ITS and smart road concept, which is, to be able to drive
various on road electrical and electronic devices and making transportation more
independent and smarter.

o Reducing the dependence on the conventional sources of electrical energy

generation at least in the transportation sector.

o Explore current scenario of speed bumps and to give a scientific method to

develop energy harvester that is able to produce large scale electrical power.
 o Keep the primary function of the speed bump, which is to reduce the speed of
the vehicle on road, and at the same time, harvest significant amount of energy.

o Give a scientific methodology to build such a harvester with supported

theoretical modelling, simulation and experimental results.

o Push the study of speed bumps/humps to make it more attractive and exploring
the way which can increase its functionality.

Thesis Organization
The motivation and organization of the thesis are included in chapter 1. Background and
the literature review including history of speed bumps, applications, its effects on vehicle
dynamics, and previous works on the speed bump had been discussed in detail in chapter 2.
Chapter 3 covers the details design of speed bump and energy harvester. The theoretical
modelling has been introduced and discussed in detail in chapter 4. Chapter 5 introduces the
experimental setup for a lab test and on road test. Results of chapter 4 and 5 have been
discussed in chapter 6 of the thesis. Next, conclusion and future works has been discussed in
chapter 7.

Speed bump and speed humps

Speed bumps/humps are a common traffic calming device that uses vertical deflection
to slow down vehicles in order to improve traffic safety [32]. Geometrically speaking, speed
bumps/humps are an elevated profile on the road defined by its base length, height and width.
As described by Parkhill and his co-authors in the “Updated Guidelines for the Design and
Application of Speed Humps” [33], “A speed bump is a raised pavement area across a roadway.
Speed bumps are typically found on private roadways and parking lots and do not tend to
exhibit consistent design parameters from one installation to another. Speed bumps generally
have a height of 3 to 6 inches (76 to 152 mm) with a travel length of 1 to 3 feet (0.3 to 1 m)”.

On the other hand, they mention, “a speed hump is also a raised area in the roadway
pavement surface extending transversely across the travel way. Speed humps are sometimes
referred to as “pavement undulations” or “sleeping policemen”. Most agencies implement
speed humps with a height of 3 to 3.5 inches (76 to 90 mm) and a travel length of 12 to 14 feet
(3.7 to 4.3 m). Speed humps are generally used on residential local streets. From an operational
standpoint, speed humps and bumps have critically different impacts on vehicles. Within typical
residential operational speed ranges, vehicles slow to about 20 mph (32 km/h) on streets with
properly spaced speed humps. A speed bump, on the other hand, causes significant driver
discomfort at typical residential operational speed ranges and generally results in vehicles
slowing to 5 mph or less at each bump”.

They have given a clear instruction on what to be called a speed bump and hump and
their clear differences. According to them, their functioning and area of installation varies.
Speed bumps, as they mentioned, is a narrow width, sharply inclined profile, whereas, speed
bumps are long width and have lower angle of slope making it convenient for the usage in the
residential and public areas. Both have their advantages and disadvantages over each other and
hence, suitable for a specific purpose on the streets and the highways.

Traffic calming and Speed bump/hump history

Although, the history of speed bumps/humps is not much clear to us, one of the earliest
known usages of speed bump was reported in 1906, in the town of Chatham, New Jersey,
United States, as a raised crosswalk 5 inches above the road [34]. Arthur Holly Compton, Nobel
Laureate in physics, is one of the earliest known people who actually came up with the
forerunning design of present day speed bump profile, which was more gentle, elongated, and
ramped in nature [35]. He called it the “Holly hump” in 1953. Ever since, the usage of speed
bumps have become a common practice across the world and it has been effectively used to
reduce the average speed of the vehicles in areas where human traffic interaction is high.

As traffic logic suggests[36] , In Europe, the traffic calming began in around 1960s Frustrated
by cut-through traffic rendering their streets unsafe, residents of the Dutch city of Delft turned their
street into an obstacle course for motor vehicles and a safe haven for their children. This first traffic
calming solution, called "living yards", or "Woonerven", slowed traffic and lessened volume with
the placement of tables, benches, sand boxes, and parking bays extending into the streets.
Woonerven were endorsed by the government nearly a decade later in 1976.

In the following years, the idea spread to other countries around the world. Regulations
and laws were created to govern the dimensions and locations of the woonerf designs. By 1990,
myriads of streets in countries such as Austria, Denmark, France, Germany, Israel, Japan,
Sweden, and Switzerland were similarly calmed.
 While effective for small low-volume streets, the woonerf designs slowed vehicles to 9
mph and were thus impractical for larger and more frequently traveled roads. The theory of
employing physical measures to deter vehicle speed had already proven effective and
experimentation began to conceive of similar ideas that would be less costly and more
adaptable to larger streets. Two types of measures were considered in addition to Woonerven;
diversions such as street closures or one-way streets and physical deterrents such as speed
humps and similar traffic calming measures. These traffic calming measures were judged to be
the most efficient and cost-effective of the three alternatives.

Even though, the history of speed bump is long enough, not too much has been thought
about harvesting energy out of them. However, an extensive study on its shape, profile, and
effects on vehicle dynamics and road handling has been done in the past several decades
making it one of the important areas of study among the researchers and engineers working in
the area of vehicle dynamics.

Profile and design of speed bumps/humps

There are different kinds of profiles and shapes of speed bump available in the market
for the commercial usage as mentioned previously. LaToya Johnson and A.J. Nedzesky, in their
study done in 2003 [37], excellently compared different shapes of common speed hump
profiles. According to them, most common shapes of speed humps, also true in case of bumps,
are circular, parabolic and flat topped as shown in the Figure 2-1.

Different common speed bump and hump profiles [37]

Having different impacts on the vehicles and usages, speed bumps/humps have evolved
with the course of time and due to extensive research done in the area of interaction of
vehicles and the speed bumps/humps. Different profiles and shapes have been studied to find
the impact on the vehicle dynamics. Moreover, There are numerous attempts made to optimize
the shape and size of the hump in order to reduce the impact on the driver and the
vehicle.[38]–[46]

Speed bump effect on vehicle dynamics

It has been widely talked that different shapes and profile of the speed bumps
causesdifferent changes in vehicle dynamics and effects the passenger accordingly. On one side,
speed bumps/humps effectively calm traffic speed to protect pedestrians, on the other side, it may
cause vehicle damage and passenger discomfort. Detailed study shows that the vehicles travelling
faster on a bump and cause backbone damage to the passenger [47]. The ride comfort is a very
important issue when it comes to speed bump design and analysis. As concluded by, Smith, McGhee
and Haley, in their report, “The prediction of passenger riding comfort from acceleration data”,
1976,

τ the values of these magnitude weighted rms values ranges roughly from 0 to 0.04 g for smooth
(interstate highway) rides, 0.04 to 0.06 g for medium rides, and above 0.06 for rough rides. In
Sweden, an evaluation of spinal stress in bus drivers against ISO 2631-5 suggests that a bus driver
shall encounter less than 150 bumps in a day at the maximum speed 10 km/h (6.25 mph) [49].
On the other hand, extensive research has been done on effectiveness of the speed
bump on velocity control of the vehicle. Studies show that, by and large, speed bumps are the
most effective way to control the velocity of the moving vehicles on the road [50], [51].
Alongside this, there have been various attempts to showcase the effects of speed
bumps/humps and cushions on the handling of the vehicle[52], [53].

Energy harvesting sources

Energy harvesting is the field where the electrical energy is trapped from the surrounding
operating environment. As described by Priya and Inman in Energy Harvesting Technologies, [54]
,there are basically three energy harvesting sources, piezoelectric, thermoelectric and
electromagnetic energy. Among these three energy harvesting sources, piezoelectric and
thermoelectric have widely been explored and discussed in the literature[54]. There are several
instances in the news where people have used piezoelectric devices on the road and speed bump in
order to generate electrical energy [55], [56]. Whereas, Andriopoulou Symeoni in his research,
showcased the way to harvester energy from roads using thermoelectric devices[57]. However, in
both piezoelectric and thermoelectric harvesting techniques, the scope of energy generation is very
limited, maximum to the scale of micro watts. Hence, it can’t be a replacement of conventional
sources of energy generation. Of these three sources, the most promising source seems to be
electromagnetic energy harvesting which is capable of generating significant amount of electric
energy which could be used for various applications. Surprisingly, not much has been done in this
area except some independent companies and researchers have done harvesting from speed
bumpsand roads using electromagnetic generator and simple mechanical crankshaft motion
[58]–[65] but, either they lack the scientific approach or simply the energy produced in their
concept is not sufficient to supplement the existing infrastructure. In another research done by
Zhang [66], the use of linear generator to produce large scale electrical power is pretty
impressive but its area of implementation is in the tunnels and highway and still lacks much
power to run road side electrical equipment.

In this research, both effectiveness and amount of power generated is significant and
can supplement and support the existing infrastructure. To summarize, when a vehicle touches
a speed bump, the speed bump receives the impulsion energy transferred from vehicle, which
provides one possible energy source to be regenerated to power road-side devices. Harvesting
the vibration energy from speed bumps may become a valid solution in some areas where grid
electricity is economically unavailable for applications such as, to power traffic lights, warning
sign or traffic sensors. The theoretical results show us that the project is capable of achieving an
electrical output of more than 1 KW

The energy crisis led to the idea of generating power using speed breaker. First to make
use were South African people, their electrical crisis has made them to implement this method
to light up small villages of the highway. The idea of basic physics to convert the kinetic energy
into electrical energy that goes waste when the vehicle runs over the speed-break was used.
Since then a lot has been done in this field. The idea caught our working team and we have
decided to develop such a project that will produce more power and store it for use at night
time as it proves to be a boon to the economy of the country.

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 will both help
them slow down and harvest some of that coasting energy. The weight of a car is used to throw
a lever, explains Gerard Lynch, the engineer behind the Motion Power 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.

IIT Guwahati has evaluated the machine and recommended it to the Assam ministry of power
for large scale funding. IIT design department says it is a very viable proposition to harness
thousands of megawatts of electricity untapped across the country every day.

Block diagram of energy harvesting using crank slider mechanism

Design of Speed bump energy harvester
Area of installation
The speed bump energy harvester is primarily designed to harvest energy from the
vehicles clocking in and out of the administrative parking lot of the State university of New York
at Stony Brook, NY. Since, it was to be installed in the parking lot, speed bump was suitable for
the purpose. The goal was to reduce to speed of the vehicle entering and exiting the parking lot
below 15 miles/hour and at the same time generating electrical energy which would be used
for various clock in/out devices such as monitoring camera, shutter gate and various other
monitoring sensors. However, the research was conducted in a very generic way and the
designed harvester was suitable for the on-street power generation and applications as well.

Concept development
The concept of speed bump energy harvester is to absorb the kinetic and potential
energy of the vehicle, while vehicle runs over the speed bump. Unlike the conventional speed
bumps as defined by the Institution of Transportation Engineers[67], this concept is based upon
a linearly moving speed bump which, when comes in contact with a vehicle, generates a stroke
like motion, which in turns, translates the linear motion of the speed bump into rotational
motion with the help of a rack and pinion gear assembly. It uses any linear motion or vibration
caused by the vehicle impact onto the bump, and uses it to produce large scale electrical
power. This novel speed bump harvester concept is based on the previous research in large-
scale energy harvesting. In research field of large scale vibration energy harvesting, L. Zuo and
etc. did pioneering investigation to regenerate large scale energy with high energy conversion
mechanism which proposes a mechanical motion rectifier (MMR) to convert linear up-down
vibration into uni-directional rotation of generator to regenerate electrical power from
vibration of vehicle absorber and ocean wave [26]–[29], [31], [68]. The design presented in the
paper is the forerunning concept of the MMR system and is used in this research of speed
bump energy harvesting. This project uses the same technique to increase the overall energy
generation capacity. MMR is discussed in details in the later section of energy harvesting
module.

The concept development phase is described in the following flow chart in Figure 3-1.
The prototype is broken into 4 different modules which includes, Vehicle dynamics, Speed
Bump, energy harvesting, and last, energy storage. The speed bump energy harvester is
composed of the speed bump module and energy harvesting module. The system level design is
done only to the speed bump and energy harvesting module also up to an extent, energy
storage module. Vehicle dynamics module, being an input, is kept as a variable.

Vehicle Speed Bump Energy Energy

Dynamics Harvesting Storage

Module
Module Module Module

Schematics of the speed bump energy harvester

Rest Position During Stroke

Motion of the speed bump energy harvester during resting position and stroke

Side view of the speed bump energy harvester combined with the speed bump module
 A common car on commercial circular speed bump

Speed bump energy harvester system design, 3-D modelling & prototype

The proposed speed bump energy harvester is made up of various smaller components
which are assembled in order for it to function. There are two main part or modules of speed
bump energy harvester which are separated according to their functionality. First, the energy
absorber or the speed bump cover and, second, the energy harvester. These two main modules
further have smaller units which are discussed in detail in the following section.

Speed bump module

This module includes the speed bump cover, the connecting rod, speed bump cover
base, linear bearings, linear bearing blocks, linear shafts and most important, springs. All these
parts of the module bear most of the heavy loads which is set upon the system. This module is
responsible for diverting the potential and kinetic energy of the vehicle to the harvesting
module which is then used for energy harvesting purpose. Among all these parts, speed bump
cover, connecting rod, linear shafts, and, linear bearing blocks, base plate are fabricated in the
machine shop and linear bearings and springs are procured according to the estimated
calculations.

Speed bump cover

Speed bump cover profile is chosen to be flat topped, which is one of the most common
shapes for the speed bumps, with a height, h, of 3.5 in (0.0889 cm), length of 9 ft and width or
cross sectional length, L (L1+L2+L3), of 14.5 in. Cast iron is used for building the prototype with
three rectangular shaped sheets of 0.2 in thickness, welded together with adjacent angle of 150
degree from the top plate giving it a flat topped shape. Mass of the speed bump is 150
kilograms. Figure 3-5 (a), (b) illustrates the 3-D design and fabricated speed bump cover
underneath which springs and energy harvesting unit is kept. Figure 3-6 (a), (b) and Figure
illustrates the cross sectional 2 D drawing and top view 3-D model of the speed bump cover.

Connecting rod

The only link between the two modules and is responsible for transferring the load of
the vehicle to the harvesting module. At time of action, the entire load is carried by this
connecting rod and thus, made of stainless steel 440 in order to withstand the shock and
carrying load effectively. The length of the connecting rod is set at 5 in

Speed bump cover base

It is a thin plate of aluminum with 0.25 in of thickness and along with length of the plate,
rectangular ribs are welded across the length plates in order to give it more bending stiffness.

Linear bearings and shafts

The speed bump cover freely rests on the springs and to provide it a linear movement,
linear shaft and the linear bearings, which rest on the bearing blocks, are used. Since, linear
shafts have to withstand heady loads, the material chosen for it is 440 stainless steel which is
same material as being used for connecting rod.

Springs and its selection

Spring selection is one of the most critical parts of the system design process since it
determines the proper functioning, load capacity and self-generating capacity of the speed
bump energy harvester. The time for speed bump to rebound to its original position can be
estimated by a quarter period of time according to its natural frequency. The natural frequency
of speed bump can be expressed as

Where fn , kb , mb , and me will be the natural frequency of speed bump, spring stiffness,
mass of speed bump and the equivalent mass of energy harvester, which will be introduced in
the later section. Assuming that the time between the front and rear axles of vehicle passing
through the speed bump is Tv , then
Substitute Eq. (1) into (2),

Energy harvesting module

Energy harvesting module comprises of several small and critical components such as
rack and pinion gear system, gear box, Brushless DC motor/generator, couplings, bearings, and
the most important, one way clutches, which help achieving the mechanical motion
rectification. The details of the energy harvesting module components are discussed in the
following sections

Brushless DC motor (BLDC motor)

Brushless DC motors are more efficient as there is not brushes and hence, the chances
of any friction are removed. Also, BLDC motor can work as a generator and hence, a 3 phase,
single shaft BLDC motor has been used for the prototype. Detailed description of the motor can
be found here.

Harvester casing and sealing

The energy harvesting module is encased in a cuboid and sealed with sealing material to
ensure that no water comes inside the electrical or mechanical part of the harvester. The
cuboid is made of aluminum to avoid any kind of rust or corrosion. The connecting rod moves
linearly through the harvesting case and it the only opening of it. In order to ensure the sealing
of the hole, two O rings are placed, one at the top and the other at the bottom of the top plate
of the harvester case. These O rings are specially placed in a grove cut with the same depth as
the wire diameter of the O rings so that they can be placed perfectly. Then bottom and the top
O rings are further fixed and sealed with the help of an aluminum plate or top seal plate.

Experimental Analysis of Speed breaker system

Dynamic performances of the fabricated prototype are measured by a dynamic

measurement system in lab. In order to evaluate the dynamic response of the harvester to
vibration excitation, multiple-channel measurement system is set up. Laser displacement
sensor is used to measure movement of speed bump cover. Accelerometer measures
acceleration of the vibration speed bump cover. The harvested electricity can be measured by a
circuit for three phase voltage. The test is to measure the electrical power output and
performance of speed bump energy harvester by jumping on speed bump cover.
 INTRODUCTION TO CAD/CAM/CAE

The Modern world of design, development, manufacturing so on, in which we have

stepped can’t be imagined without interference of computer. The usage of computer is such
that, they have become an integral part of these fields. In the world market now the
competition in not only cost factor but also quality, consistency, availability, packing, stocking,
delivery etc. So are the requirements forcing industries to adopt modern technique rather than
local forcing the industries to adapt better techniques like CAD / CAM / CAE, etc.,
The Possible basic way to industries is to have high quality products at low costs is by
using the computer Aided Engineering (CAE), Computer Aided Design (CAD) And Computer
Aided Manufacturing (CAM) set up. Further many tools is been introduced to simplify & serve
the requirement CATIA, PRO-E, UG are some among many.

This penetration of technique concern has helped the manufacturers to

a) Increase productivity
b) Shortening the lead-time
c) Minimizing the prototyping expenses
d) Improving Quality
e) Designing better products
CAD: Computer Aided Designing (Technology to create, Modify, Analyze orOptimize the design
using computer.
CAE: Computer Aided Engineering (Technology to analyze, Simulate or Studybehavior of the cad
model generated using computer.
CAM: Computer Aided Manufacturing (Technology to Plan, manage or controlthe operation in
manufacturing using computer.
Need for CAD, CAE &CAM:
The usage of CAD CAE & CAM have changed the overlook of the industries and developed
healthy & standard competition, as could achieve target in lean time and ultimately the
product reaches market in estimated time with better quality and consistency. In general view,
it has lead to fast approach and creative thinking.
ADVANTAGES:
o Cut off of the designing time
o Cut off of the editing time
o Cut off of the manufacturing time
o High & controlled quality
o Reduction of process cost.
o Consistency
Maintenance of Universal accessing
o data
DRAWBACKS:
a. Requires skilled operators
b. Initial setting & assumption consumes time
oSetting cost is more
c. Over heads are high and
d. Applicable if production is high

INTRODUTION TO SOLIDWORKS
Solid works is a 3d Solid displaying bundle which enables clients to model full Solid
models in a mimicked domain for both plan and examination. In Solid works; you outline
thoughts and explore different avenues regarding distinctive plans to make 3d models. Solid
works is utilized by understudies, planners, engineers, and different experts to deliver basic and
complex parts, gatherings, and drawings. Outlining in a demonstrating bundle, for example,
Solid works is helpful on the grounds that it spares time, exertion, and cash that would
somehow or another be spent prototyping the plan.

Solid Works Components - Parts

Before we start taking a gander at the product, it is essential to comprehend the distinctive
parts that make up a Solid works demonstrate.

Part:

 The first and most essential component of a Solid works display is a section.
  Parts comprise of primitive geometry and highlight, for example, expels, insurgencies,
lofts, clears, and so forth.
 Parts will be the building obstructs for the greater part of the models that you will make.

Assembly:

 The second part is the gathering. Congregations are accumulations of parts which are
amassed in a specific form utilizing mates (limitations).
 Any complex model will generally comprise of one, or numerous congregations.

Drawing:

 The third and last part in strong works is the drawing.

 A drawing is the average approach to speak to a 3d model with the end goal that any
architect (or producer) can reproduce your part.
 Drawings are essential since they give a standard method for sharing your outline.

Solid Works – Let’s Begin

Solid Works Default Page

 By default, no document is opened naturally when you begin the program.

 To make another document, tap on record - new or tap the new document symbol in
the fundamental toolbar.
 This will open the new solid works document wizard.
Part selection window in Solid Work

 Let's start by making another part.

 To do this, tap on part, at that point alright. When you do this, you will be brought into
the displaying view which should open a few toolbars and sheets.

Terminology

These terms show up all through the Solid works programming and documentation.

1. Origin: shows up as two blue bolts and speaks to the (0, 0, 0) facilitate of the model. At
the point when a draw is dynamic, a portray source shows up in red and speaks to the (0, 0,
0) organize of the outline. You can add measurements and relations to a model beginning,
yet not to an outline starting point.

2. Plane: level development geometry. You can utilize planes for including a 2d draw,
segment perspective of a model, or an unbiased plane in a draft highlight, for instance.

3. Axis: straight line used to make display geometry, components, or examples. You can
make a pivot in various ways, including meeting two planes. The Solid works application
makes brief tomahawks certainly for each cone shaped or barrel shaped face in a model.

4. Face: limits that assistance characterize the state of a model or a surface. A face is a
selectable region (planar or non-planar) of a model or surface. For instance, a rectangular
strong has six countenances.
 5. Edge: area where at least two countenances meet and are consolidated. You can choose
edges for portraying and dimensioning.

6. Vertex: time when at least two lines or edges cross. You can choose vertices for
portraying and dimensioning.

User Interface

The strong works application incorporates UI instruments and abilities to enable you to make
and alter models proficiently, including:

1. Windows capacities: the strong works application incorporates commonplace windows

capacities, for example, dragging and resizing windows. Huge numbers of similar symbols, for
example, print, open, spare, cut, and glue are likewise part of the strong works application.

2. Solid works archive windows: strong works record windows have two boards. The left board,
or administrator sheet, contains:

Feature Manager /Design Tree

Specification Tree

Showcases the structure of the part, gathering, or drawing. Select a thing from the element
administrator configuration tree to alter the basic outline, alter the element, and smother and
unstifle the element or segment, for instance.
  Property administrator: gives settings to many capacities, for example, outlines, fillet
components and get together mates.

Extrude Tool Box

 Configuration manager: gives you a chance to make, select, and see numerous
arrangements of parts and gatherings in a report. Arrangements are varieties of section
or gathering inside a solitary report. For instance, you can utilize designs of a dash to
determine diverse lengths and distances across.

Configuration Box

 Mouse catches: mouse catches work in the accompanying ways:

 Left: chooses menu things, elements in the illustrations territory, and protests in the
element director configuration tree.

 Right: shows the setting delicate easy route menus.

 Middle: turns, container, and zooms a section or a get together, and dish in a drawing.

 Mouse signals: you can utilize a mouse motion as an easy route to execute an order, like
a console alternate way. When you learn order mappings, you can utilize mouse
 motions to summon mapped orders rapidly. To actuate a mouse signal, from the
illustrations region, right-drag in the motion bearing that compares to the charge. When
you right-drag, a guide shows up, demonstrating the order mappings for the signal
bearings.

A get together is a mix of at least two sections, likewise called segments, inside one solid works
report. You position and arrange segments utilizing mates that shape relations between
segments.

This lesson examines the accompany

 Adding parts to a get together

 Moving and turning parts in a get together

 Creating show states in a get together

Modeling Tools

Extrude:

You can utilize similar techniques you learned in lesson 1 to make the base for another part.

1. Click new (standard toolbar) and open another part.

2. Click expelled manager/base (highlights toolbar) and select the front plane.

3. Sketch a corner profile starting at the inception.

4. Click shrewd measurement (measurements/relations toolbar) and measurement the

profile

5. Click leave draw (outline toolbar) to leave the portray.

6. Under direction1:

7. Set end condition to daze.

8. Set profundity to 4.5.

9. Click to make the expulsion.

Extrude Cut:

1. Click expelled supervisor/base (highlights toolbar) and select the front plane.

2. Sketch a corner profile starting at the source.

3. Click keen measurement (measurements/relations toolbar) and measurement the

profile

4. Click leave outline (portray toolbar) to leave the draw.

5. Under direction1: set end condition to daze.

6. Set profundity to 4.5.

7. Click to make the expulsion.

Revolute:

1 .Click revolute supervisor/base (highlights toolbar) and select the front plane.

2. Sketch a corner profile starting at the root.

3. Click keen measurement and measurement the profile.

4. Click leave outline (draw toolbar) to leave the portray.

5. Under direction1: set end condition to dazzle.

6. Set profundity to 4.5.

7. Click to make the expulsion.

Revolute Cut:

1. Click revolute cut (highlights toolbar) and select the front plane.

2. Sketch a corner profile starting at the beginning.

3. Click shrewd measurement and measurement the profile to 99.54 mm.

4. Click leave portray (outline toolbar) to leave the draw.

5. Under direction1: set end condition to daze.

6. Set profundity to 4.5.

7. Click to make the expulsion.

Circular Pattern

Make 7 gap chamber expulsions with cuts and filets equitably divided about the focal pivot of
the part utilizing the roundabout example instrument.

1. On the components toolbar, grow the straight example fly out toolbar and snap
roundabout example.

2. In the property chief, under parameters:

3. Select the edge in the focal point of the part for design pivot.

4. Select equivalent separating to design the quantity of examples consistently around the
hub inside 360°.

5. Set number of examples to

6. Click in components to design.

7. In the fly out element administrator configuration tree in the illustrations range, select
the last components (cut-extrude2).
Fillets:

To choose the edges for including the round shapes with required thickness as appeared in
beneath by utilizing expel, for adding the material to made the shape with thickness of 5mm
circle its appeared as underneath

Hole:

Hole apparatus we can apply the expel the material on the surface of brake rotor for the
required breadth as appeared in beneath

CAD Modelling
This project is concerned with the explanation of the mechanism of power
generationfrom speed breakers. The load of vehicle is transmitted to crankshaft module. After
that,reciprocated motion is converted into rotary motion by the arrangements. Here, the pinion
axis is connected with the sprocket arrangement. Achain connects both of the sprockets which
transmits the power from the sprocketto the small sprocket.
For this, the speed of the large sprocket is multiplied with therotary of the small
sprocket. The small sprocket’s axis is paired with a geararrangement. Two gears having
different dimensions are used here. The gear wheelhaving the large diameter is connected with
the axis of the small sprocket. Since, theincreasing speed of the small sprocket wheel is passed
over gear wheel of largediameter. The small gear is connected to the large gear. When the large
gear is rotated,it increases the amount of speed of the small gear and multiplies with speed to
get moreintensity. Then, the Final speed is so much high. This speed is comparatively enough
torotate the rotor and also sufficient to fed rotor. The rotor rotating within magnetic
statorremoves the magnetic flux. Then it produces the electromotive force. Then thisgenerated
emf goes to an inverter, where the emf is regulated. Finally, this emfis now sent to the battery
and can use at night for producing power to street lights.

Physical model construction details

The various machine elements used in the construction of power hump are
 Crank Module
 Speed breaker dome with support frame
 Shaft
  Springs
 Electric dynamo
A dome is mounted on four springs and in the bottom, a crank is clamped. The crank 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.

Working

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 domelike device likely
to be speed breaker. Whenever the vehicle is allowed to pass over the dome it gets
presseddownwards 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 motionof 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. theseshafts
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 ofsouth and north poles, an E.M.F (electro motive force) is induced
in it. So, for inducing the E.M.F armature coil has torotate, 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 isgenerated in both the directions; to convert this power
into one way a special component is used called zenor diode forcontinuous supply. All this
mechanism can be housed under the dome, like speed breaker, which is called HUMP.
Theelectrical output can be improved by arranging these POWER HUMPS in series. This
generated power can beamplified and stored by using different electrical devices.
CAD Modelling Parts

Speed breaker dome and upper support frame

Bottom support frame

Crank Shaft Module

Connecting link
 DESIGN CALCULATIONS

Design of springs
Material of the spring
ASTM A228 Steel (G=80000 MPa)
Wire diameter of the spring, d = 4mm
Outer diameter of the spring, D = 48 mm
Length of the spring, l = 182mm
Number of coils, n = 10
Mean coil diameter = D-d
= 48 -4
= 44mm
Stiffness of the spring, k =(G×d4)/ (8 × D3 × n)
= 80 × 1000 x 44
8 × (44)3 ×10
= 3.00 N/mm
Calculation of Load
Stiffness of springs k =
load/deflection
Therefore, load, w = k × deflection
= 3 * 50
= 150 N
(We assume maximum deflection as 50 mm) as we are using two springs of same specification
total load W = 4 × w
= 4 × 150
= 600 N
= 61.16 kg

Calculation of torque

Torque, T = force × perpendicular distance

= 600 × 25×10-3 (perpendicular distance= 25mm)

= 15 N-m

Speed Ratio = 1:1

Estimated power output

Power = 2 π N T /60

= 2*π*30*15/60

= 47 Watts

Cost Analysis

The cost of fabrication is very low. For this reason, this project is comparatively so much
effective. The technique of generating power within such a low cost will be very suitable.

Below tabular column includes details about list of components, quantities and price details

S.No. Component Quantity Price

1 Springs 4 1200
2 Crankshaft Module 1 1000
3 Chain 1 200
4 Motor 1 200
5 Frame Structure 1 5000
6 LED Module 1 50
7 Fasteners 5 100

CONCLUSION
In this project we discover a technology to generate electricity from speed breakers
which is reliable and obviously will help to save our natural resources. Since, lot of electricity of
power plants. Due to over population, the power generation has become insufficient to fulfill
our requirements. This project can help to solve energy crisis very easily. The reason why this
model was used more than all the other features are because other models would not have as
much effect on the complete system. By changing the size and desirable price, weight and
capacity out how the price, weight and capacity were scaled. Much was learned on how to and
not to conduct a survey. The design is for concept demonstration purpose only. In real
conditions, springs with higher stiffness are to be used to get output.

This concept is so important & here the reason behind this:

  Power generation with low cost.
 Environment friendly power generation.
 Comparatively less floor area required.

 Man power is not necessary.

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