POWER GENERATION USING SPEED

BREAKER MECHANISM

1
 Chapter Number 1

Introduction of the project

1. INTRODUCTION
2. SCOPE OF THE PROJECT

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 Generation of Electricity through Speed Breaker Mechanism

1. INTRODUCTION:-
This project 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. In this model we show that how we
can generate a voltage from the busy traffic. Conversion of the mechanical energy into
electrical energy is widely used concept. It’s a mechanism to generate power by
converting the potential energy generated by a vehicle going up on a speed breaker into
rotational energy. We have used that simple concept to the project.

2. SCOPE OF THE PROJECT:-

The utilization of energy is an indication of the growth of a nation. For example,
World average per capita electricity consumption is 2730 kWh compared to Pakistan’s
per capita electricity consumption of 451 kWh. Pakistan has an installed electricity
generation capacity of 22,797MW. The average demand is 17,000MW and the shortfall
is between 4,000 and 5,000MW. One might conclude that to be materially rich and
prosperous, a human being needs to consume more and more energy.
Pakistan is facing serious energy crisis at this time .Pakistan as third world developing
country is lot affected by this energy crisis in the world .The major issue is electric crisis
which is known as load shedding Pakistan’s small manufacturing markets are lot affected
by the rise of energy prices.
By just placing a unit like the “Power Generation Unit from Speed Breakers”, so much of
energy can be tapped. This energy can be used for the lights on the either sides of the
Roads and thus much power that is consumed by these lights can be utilized to send power
to these villages.

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 Generation of Electricity through Speed Breaker Mechanism

Chapter Number 2

Demonstration of the Project

1. WORKING PRINCIPLE
2. BLOCK DIAGRAM

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 Generation of Electricity through Speed Breaker Mechanism

1 WORKING PRINCIPLE:-
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 the sprocket
arrangement. The sprocket arrangement is made of two sprockets. One of larger size and
the other of smaller size (free wheel). 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. The axis of the smaller sprocket is coupled to a fly wheel. The fly wheel is
coupled to the shaft at axis of the smaller sprocket. Hence the speed that has been
multiplied at the smaller sprocket wheel is passed on to this fly wheel of larger dimension.
The smaller sprocket is coupled to the larger fly wheel. So as the larger fly wheel rotates
at the multiplied speed of the smaller sprocket, the smaller sprocket following the larger
sprocket still multiplies the speed to more intensity. Hence, although the speed due to the
rotary motion achieved at the larger sprocket wheel is less, as the power is transmitted to
fly wheel, finally the speed is multiplied to a higher speed. This speed which is sufficient to
rotate a shaft connected to generator. The rotor (shaft) rotates the generator. The
generator produces the DC current. This DC current is now sent to the storage battery
where it is stored during the day time. This current is then utilized in the night time for
lighting purposes on the either sides of the road to a considerable distance.

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 Generation of Electricity through Speed Breaker Mechanism

2 BLOCK DIAGRAM:-

SPEED BRAKER RACK & PINION

AND CHAIN
Fly wheel
ARRANGE
SPROCKET
MENT ARRANGEMENT

GENERATOR INVERTER STREET

BATTERY
LIGHTS

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 Generation of Electricity through Speed Breaker Mechanism

Chapter Number 3

Modeling, Simulation and

Results
1. FABRICATION DETAILS
2. FABRICATION MODEL SHOWING INNER
PARTS
3. MATERIALS USED
4. SPECIFICATIONS
5. ADVANTAGES
6. DISADVANTAGE

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 Generation of Electricity through Speed Breaker Mechanism

1. FABRICATION DETAILS:-
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. 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. 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. A rack
which are 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.
A bicycle sprocket and chain arrangement of standard make is fitted with the larger
sprocket on the top shaft and its smaller sprocket on the bottom shaft. The sprocket wheels
are welded to the shafts. 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. 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.

2. FABRICATION MODEL SHOWING INNER PARTS:-

Wires are connected to the terminals of the DC generator and its other ends are
connected to a Lead-Acid battery. Another wire is taken from these points on the battery
and its other ends are connected to the positive and negative terminal of an inverter. An
output wire from the inverter is sent to the light.

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 Generation of Electricity through Speed Breaker Mechanism

3. MATERIALS USED:-
• Rack - Mild steel
• Pinion - Mild Iron
• Sprocket wheels- Mild steel
• Chain - Mild steel
• Spur gears - Cast Iron
• Springs - Mild steel
• Shaft - Mild steel
• Speed breaker - Mild steel

4. SPECIFICATIONS:-
Generator - 12v DC generator

Battery - lead acid battery

Inverter - 250 w AC inverter

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 Generation of Electricity through Speed Breaker Mechanism

5. ADVANTAGES:-
 Pollution free power generation.
 Simple construction, mature technology, and easy maintenance.
 No manual work necessary during generation.
 Energy available all year round.
 No fuel transportation problem.
 No consumption of any fossil fuel which is non-renewable source of energy.
 Uninterrupted power generation during day and night.
 Maximum utilization of energy.
 Load to the piston cylinder arrangement is freely got by movement of vehicles.
 No fuel storage is required.
 .It will work with light weight and heavy vehicle

6. DISADVANTAGE:-
 We have to check mechanism from time to time
 It can get rusted in rainy season.

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 Generation of Electricity through Speed Breaker Mechanism

Chapter Number 4

Rack, Pinion and Sprocket

1. RACK AND PINION
2. SPROCKET
3. DRIVE ARRANGEMENTS
4. BEST ARRANGEMENTS
5. OTHER ACCEPTABLE ARRANGEMENTS
6. LEAST RECOMMENDED ARRANGEMENTS
7. SPROCKET DIMENSIONAL
SPECIFICATIONS

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 Generation of Electricity through Speed Breaker Mechanism

1. RACK AND PINION:-

 A rack and pinion gears system is composed of two gears. The normal round gear is
the pinion gear and the straight or flat gear is the rack.
 A rack and pinion is a type of linear actuator that comprises a pair of gears which
convert rotational motion into linear motion. The circular pinion engages teeth on a
linear "gear" bar which is called the “rack“.

 Rotational motion applied to the pinion will cause the rack to move to the side, up to
the limit of its travel.
 For example, in a rack railway, the rotation of a pinion mounted on a locomotive or
a railcar engages a rack between the rails and pulls a train along a steep slope.
 The rack and pinion is also used to convert between rotary and linear motion. The
rack is the flat, toothed part, and the pinion is the gear. Rack and pinion can convert
from rotary to linear of from linear to rotary motion.
 It converts the linear motion of the speed breaker into the circular motion needed to
turn the shaft.

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 Generation of Electricity through Speed Breaker Mechanism

2. SPROCKET:-
A sprocket or sprocket-wheel is a profiled wheel with teeth or cogs that mesh with
a chain, track or other perforated or indented material. The name "sprocket" applies
generally to any wheel upon which are radial projections that engage a chain passing
over it. It is distinguished from a gear in that sprockets are never meshed together directly,
and differs from a pulley in that sprockets have teeth and pulleys are smooth. The word
"sprockets" may also be used to refer to the teeth on the wheel.
Sprockets are used in bicycles, motorcycles, cars, tracked vehicles, chainsaws and
other machinery either to transmit rotary motion between two shafts where gears are
unsuitable or to impart linear motion to a track, tape etc. Perhaps the most common form
of sprocket may be found in the bicycle, in which the pedal shaft carries a large sprocket-
wheel, which drives a chain, which, in turn, drives a small sprocket on the axle of the rear
wheel. Early automobiles were also largely driven by sprocket and chain mechanism, a
practice largely copied from bicycles.
Sprockets are of various designs, a maximum of efficiency being claimed for each by its
originator. Sprockets typically do not have a flange. Some sprockets used with timing
belts have flanges to keep the timing belt centered. Sprockets and chains are also used
for power transmission from one shaft to another where slippage is not admissible,
sprocket chains being used instead of belts or ropes and sprocket-wheels instead of
pulleys. They can be run at high speed and some forms of chain are so constructed as to
be noiseless even at high speed.

3. DRIVE ARRANGEMENTS:-
Relative position of sprockets in drives should receive careful consideration. Satisfactory
operation can be secured with the centerline of the drive at any angle to the horizontal, if
proper consideration is given. Certain arrangements require less attention and care than
others are, therefore, less apt to cause trouble. Various arrangements are illustrated in the
diagrams. The direction of rotation of the drive sprocket is indicated.

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 Generation of Electricity through Speed Breaker Mechanism

4. BEST ARRANGEMENTS:-
Arrangements considered good practice are illustrated in Figs. 1, 2, 3, and 4. The
direction of rotation of the drive sprockets in Figs. 1 and 4 can be reversed.

5. OTHER ACCEPTABLE ARRANGEMENTS:-

If none of the above arrangements can be followed, an attempt should be made to use an
arrangement as illustrated in Figs. 5, 6, and 7.

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 Generation of Electricity through Speed Breaker Mechanism

When the large sprocket is directly above the small sprocket, Fig. 8, a drive cannot
operate with much chain slack. As the chain wears, shaft-center distance must be adjusted
or an idler be placed against the outside of the slack strand (near the small sprocket) to
adjust slack and keep the chain in proper contact with the small sprocket. With the drive
slightly inclined, Fig. 5, less care will be required, because the weight of the slack chain
strand helps to maintain better contact between the chain and the sprockets. Where center
distances is short, or drives nearly horizontal, the slack should be in the bottom strand,
especially where take-up adjustment is limited, Fig. 6 rather than Fig. 9. An accumulation
of slack in the top strand may allow the chain to be pinched between the sprockets, Fig. 9.
When small sprockets are used on horizontal drives, it is better to have the slack strand on
the bottom, Fig. 7, rather than on the top, Fig. 10. Otherwise, with the appreciable amount
of slack, the strands may strike each other.

6. LEAST RECOMMENDED ARRANGEMENTS:-

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 Generation of Electricity through Speed Breaker Mechanism

American sprocket manufacturers have adopted 4 specific types of sprocket

Construction styles as American Standards. In addition to the standard sprockets,
Special sprockets may be available in the same styles.
 Style A - Flat sprocket with no hub extension either side.
 Style B - Sprocket with hub extension one side.
 Style C - Sprocket with hub extension both sides.
 Style D - Sprocket with a detachable bolt on hub attached to a plate.

7. SPROCKET DIMENSIONAL SPECIFICATIONS:-

a. Bottom Diameter (B.D.):
The diameter of a circle tangent to the bottoms of the tooth spaces.
b. Caliper Diameter:
Since the bottom diameter of a sprocket with odd number of teeth cannot be
measured directly, caliper diameters are the measurement across the tooth spaces nearly
opposite.

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 Generation of Electricity through Speed Breaker Mechanism

c. Pitch Diameter (P.D.):

The diameter across to the pitch circle which is the circle Followed by the centers of
the chain pins as the sprocket revolves in mesh with the chain.
PITCH
PD =
SIN (180/Nt)

d. Outside Diameter (O.D.):

The measurement from the tip of the sprocket tooth across to the corresponding
point directly across the sprocket. It is comparatively unimportant as the tooth length is not
vital to proper meshing with the chain. The outside diameter may vary depending on type
of cutter used.
OD = (Pitch) (.6 + COT [180 / Nt])
e. Hub Diameter (HOD):
That distance across the hub from one side to another. This diameter must not
exceed the calculated diameter of the inside of the chain side bars.
f. Maximum Sprocket:
Maximum Sprocket Bore is determined by the required Bore hub wall thickness for
proper strength. Allowance must be made for keyway and setscrews.
g. Face Width:
Face width is limited in its maximum dimension to allow proper clearance to provide
for chain engagement and disengagement. The minimum width is limited to provide the
proper strength to carry the imposed loads.
h. Length thru Bore:
Length Thru Bore (or L.T.B.) must be sufficient to allow (LTB) a long enough key to
withstand the torque transmitted by the shaft. This also assures stability of the sprocket on
the shaft.

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 Generation of Electricity through Speed Breaker Mechanism

Chapter Number 5

Chain Drives
1. Chain Drives
2.Chain Drive Design
3.Vibrations
4.Avoiding vibration
5.Chain Types
6.Chain Failures

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 Generation of Electricity through Speed Breaker Mechanism

1. CHAIN DRIVES:
 Chain drives are a means of
transmitting power like gears,
shafts and belt drives
 Characteristics
 High axial stiffness
 Low bending stiffness
 High efficiency
 Relatively cheap
 History and development
 First belt drives: China
c100 BC
 First chain drives: Roman c200 AD

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 Generation of Electricity through Speed Breaker Mechanism

 Leonardo DaVinci: sketch of leaf type chain c1500 AD – many similarities to

modern chains.

 Galle chains: 19th century first mass produced roller chains (no bushes).

 Hans Renold (Switzerland)

1880 – invented modern bush
roller chain
Bush Roller Chains:
Parts of a bush roller chain,

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 Generation of Electricity through Speed Breaker Mechanism

 Terminology:

 Manufacture:
Bushes and pins: cold drawn,
cropped, turned/ground, case
hardened, ground again and shot
peened.
Side-plates are stamped from
plate.

 Assembly
Pins and bushes are press-fitted into appropriate side plates.

2. CHAIN DRIVE DESIGN:-

Chain length and center distance:
Chain must contain even integer number of links
• Hence cannot pick an arbitrary center distance and chain pitch

• Nearest chain lengths (in pitches) for a contemplated center distance, CC

, are calculated by empirical formulae like (for a two sprocket system:

Where N1and N2 is the numbers of teeth on sprockets and P is the chain pitch.

 The result of which should be ROUNDED UP to the next even number to calculate the
actual center separation, CA:

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 Generation of Electricity through Speed Breaker Mechanism

Inertial force in chain:

 In addition to the tension required to transmit power, chain tension also provides
centripetal force to move links around sprockets
 The extra inertial force, Fcf, is given by:

3. Vibrations:
 Chain between sprockets can vibrate like a string

Basic
equation for natural frequency, fn, of taught string

Where F is the tension, m is the mass per unit length, L is the length and k is the mode
number

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 Generation of Electricity through Speed Breaker Mechanism

 For tight side of chain there are typically ranges of resonant frequencies given by:

Where,
Fc is the tight span tension (excluding inertial contribution)
4. Avoiding vibration:-
 To avoid the chain resonating, need to avoid having sources of excitation with
frequencies near possible resonant frequencies
 Obvious source is impact of sprocket teeth on chain
 Frequency of these occurs at:

Where ω is the sprocket rotation speed and N is the number of teeth.

5. Chain Types:-
1) Transmission chains
 Chains to transmit rotary power between shafts
 Bush roller chains are transmission chains
 For more power capacity, multi-strand transmission chains are used

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 Generation of Electricity through Speed Breaker Mechanism

2) Conveyor chain
 Rollers sit proud of links and
can roll along supporting
surface.
 Can be used for transporting
materials, as roller scan support
weight.
 Can also be used just to support
weight of chain if transmitting
power over long distances.

3) Inverted tooth (or silent) chain

 Sprocket teeth mesh with shaped links instead of rollers on chain
 Joints between links use rolling rather than sliding contact
 Profile of links are more like involute gear teeth Overall effect is to
reduce noise

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 Generation of Electricity through Speed Breaker Mechanism

4) Leaf (or lifting) chain

 Designed for lifting rather (than
power transmission)
 Do not have to mesh with sprockets,
hence no rollers
 Therefore can narrower than roller
chain with equivalent strength
 Example: fork-lift truck
6. Chain Failures:-
 Failures caused by poor selection
 Overload
 Failure of side plates due to cyclic load fatigue
 Failure of bush or roller due to impact fatigue
 Above failures can still occur due to poor installation or
maintenance
 Misalignment
 Incorrect or failed lubrication system
 If correct chain is selected, installed and maintained the overall
life is determined by wear
 Causes and effects of chain wear
 Caused by material removal as chain components slide relative to
each other
 Effect of wear is to cause the chain to gradually elongate

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 Generation of Electricity through Speed Breaker Mechanism

 As pitch increases, chain sits at larger and large radius on sprockets

 Limit is when chain jumps over sprocket teeth
 Empirical extension limits are
• 2 % for sprockets with less than 200 teeth
• 200/N % for sprockets with more than 200 teeth

 Wear life
 Typically 15,000 hours for any power, chain or sprocket size if correctly
selected, installed and maintained.

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 Generation of Electricity through Speed Breaker Mechanism

Chapter Number 6

Wheels and springs

1.Freewheel
2.Flywheel
3.Springs

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 Generation of Electricity through Speed Breaker Mechanism

1. FREEWHEEL:-
A freewheels consists of either a single sprocket or a set of sprockets mounted on a body
which contains an internal ratcheting mechanism and mounts on a threaded hub.
Mechanics:
The simplest freewheel device consists of two saw-toothed, spring-loaded discs pressing
against each other with the toothed sides together, somewhat like a ratchet. Rotating in
one direction, the saw teeth of the drive disc lock with the teeth of the driven disc, making
it rotate at the same speed. If the drive disc slows down or stops rotating, the teeth of the
driven disc slip over the drive disc teeth and continue rotating, producing a characteristic
clicking sound proportionate to the speed difference of the driven gear relative to that of
the (slower) driving gear.
A more sophisticated and rugged design has spring-loaded steel rollers inside a driven
cylinder. Rotating in one direction, the rollers lock with the cylinder making it rotate in
unison. Rotating slower, or in the other direction, the steel rollers just slip inside the
cylinder.

Advantages:
Free wheel mechanism acts as an automatic clutch, making it possible to change
gears in a manual gearbox, either up- or downshifting, without depressing the clutch
pedal, limiting the use of the manual clutch to starting from standstill or stopping.
Disadvantages:
The major disadvantage of the multiple sprocket freewheel design is that the drive-
side bearing is located inboard of the free wheel, and as sprockets were added over
time, moved the bearing farther from the drive-side axle support. This resulted in more
flexing stress is placed on the axle which can bend or even break.

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 Generation of Electricity through Speed Breaker Mechanism

2. FLYWHEEL:-
A flywheel is a rotating
mechanical device that is used to
store rotational energy. Flywheels
have a significant moment of
inertia and thus resist changes in
rotational speed. The amount of
energy stored in a flywheel is
proportional to the square of
its rotational speed. Energy is
transferred to a flywheel by
applying torque to it, thereby
increasing its rotational speed, and
hence its stored energy.
Conversely, a flywheel releases
stored energy by applying torque to a mechanical load, thereby decreasing its rotational
speed.
Energy Stored in a Flywheel:
A flywheel is shown in Fig. when a flywheel absorbs energy its speed increases and when
it gives up energy its speed decreases.
Let m= Mass of the flywheel in kg,
k = Radius of gyration of the flywheel in meters,
I = Mass moment of inertia of the flywheel about the axis of rotation in kgm2=m.k2,
N1and N2 = Maximum and minimum speeds during the cycle in r.p.m,
ω1and ω2 = Maximum and minimum angular speeds during the cycle in rad / s,
N= Mean speed during the cycle in r.p.m.

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 Generation of Electricity through Speed Breaker Mechanism

The radius of gyration (k) may be taken equal to the mean radius of the rim (R), because
the thickness of rim is very small as compared to the diameter of rim. Therefore
substituting k= R in equation (ii), we have
Δ E=m.R2.ω2.CS= m.v2.CS ( v= ω.R)
From this expression, the mass of the flywheel rim may be determined.
Notes: 1.In the above expression, only the mass moment of inertia of the rim is considered
and the mass moment of inertia of the hub and arms is neglected. This is due to the fact
that the major portion of weight of the flywheel is in the rim and a small portion is in the
hub and arms. Also the hub and arms are nearer to the axis of rotation, therefore the
moment of inertia of the hub and arms is very small.
2. The density of cast iron may be taken as 7260 kg / m3 and for cast steel, it may taken
as 7800 kg / m3.
3. The mass of the flywheel rim is given by
m= Volume × Density = 2 πR× A× ρ
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 Generation of Electricity through Speed Breaker Mechanism

From this expression, we may find the value

of the cross-sectional area of the rim.
Assuming the cross-section of the rim to be
rectangular, then
A=b× t
where b= Width of the rim, and
t = Thickness of the rim.
Knowing the ratio of b/twhich is usually
taken as 2, we may find the width and
thickness of rim.
4. When the flywheel is to be used as a
pulley, then the width of rim should be taken
20 to 40 mm greater than the width of belt.

3. SPRINGS:-
A spring is defined as an elastic body, whose function is to distort when loaded and
to recover its original shape when the load is removed. The various important applications
of springs are as follows :
1. To cushion, absorb or control energy due to either shock or vibration as in car springs,
railway buffers, air-craft landing gears, shock absorbers and vibration dampers.
2. To apply forces, as in brakes, clutches and springloaded valves.
3. To control motion by maintaining contact between two elements as in cams and
followers.
4. To measure forces, as in spring balances and engine indicators.
5. To store energy, as in watches, toys, etc.

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 Generation of Electricity through Speed Breaker Mechanism

Types of Springs:
Though there are many types of the springs, yet the following, according to their
shape, are important from the subject point of view.
Helical springs:
The helical springs are made up of a wire coiled in the form of a helix and is
primarily intended for compressive or tensile loads. The cross-section of the wire from
which the spring is made may be circular, square or rectangular. The two forms of helical
springs are compression helical springas shown in Fig. (a) and tension helical spring as
shown in Fig. (b).

Advantages:
(a) These are easy to manufacture.
(b) These are available in wide range.
(c) These are reliable.
(d) These have constant spring rate.
(e) Their performance can be predicted more accurately.
(f) Their characteristics can be varied by changing dimensions.

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 Generation of Electricity through Speed Breaker Mechanism

Conical and volute springs:

The conical and volute springs, as shown in Fig. are used in special applications where a
telescoping spring or a spring with a spring rate that increases with the load is desired.
The conical spring, as shown in Fig.(a), is wound with a uniform pitch whereas the volute
springs, as shown in Fig. (b), are wound in the form of parabolic with constant pitch and
lead angles. The springs may be made either partially or completely telescoping. This
characteristic is sometimes utilized in vibration problems where springs are used to support
a body that has a varying mass.

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 Generation of Electricity through Speed Breaker Mechanism

Torsion springs:
These springs may be of helical or spiral type as shown in Fig. The helical type may
be used only in applications where the load tends to wind up the spring and are used in
various electrical mechanisms. The spiral type is also used where the load tends to increase
the number of coils and when made of flat strip are used in watches and clocks.
The major stresses produced in torsion springs are tensile and compressive due to
bending.

Laminated or leaf springs:

The laminated or leaf spring (also known as flat spring or carriage spring) consists
of a number of flat plates (known as leaves) of varying lengths held together by means of
clamps and bolts, as shown in Fig. These are mostly used in automobiles.
The major stresses produced in leaf springs are tensile and compressive stresses.

Laminated or leaf springs. Disc or Bellevile springs.

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 Generation of Electricity through Speed Breaker Mechanism

Values of allowable shear stress, Modulus of elasticity and Modulus of rigidity for various
spring materials.

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 Generation of Electricity through Speed Breaker Mechanism

Standard Size of Spring Wire:

Standard wire gauge (SWG) number and corresponding diameter of spring wire.

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 Generation of Electricity through Speed Breaker Mechanism

Chapter Number 7

Design Parameter`s and

Limitations

1. OUTPUT POWER CALCULATIONS

2. DESIGN SPECIFICATIONS
3. SPROCKET WHEEL AND CHAIN
4. SPRINGSSPUR GEARS

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 Generation of Electricity through Speed Breaker

Mechanism :-
Output Power Calculation:-

Let us consider,

The mass of a vehicle moving over the speed breaker = 10Kg (Approximately) Height of

speed brake = 10 cm

Work done = Force x Distance

Here,

Force = Weight of the Body

= 10 Kg x 9.81

= 98.1 N

Distance traveled by the body = Height of the speed brake

= 10 cm

Output power = Work done/Sec

= (89.1 x 0.10)/60

= 0.1485 Watts (For One pushing force)

Power developed for 1 vehicle passing over the speed breaker arrangement for one
minute

= 0.1485 watts

Power developed for 60 minutes (1 hr) = 8.91 watts

Power developed for 24 hours =

213.84watts
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 CHAPTER-8 ESTIMATION AND
COSTING
ESTIMATING:-
It is an art to find out the cost which is likely to be included on the manufacturing
of an article before manufacturing it an acutely. There it is calculation probable
cost of an article before manufacturing. It is also included per determination of
the quantity and quality of material labour required etc.
Estimating required highly technical Knowledge about manufacturing methods
and operation time etc.
IMPORTANCE OF ESTIMATING:-
In every organization before starting actual production estimation is done, There
fore accurate estimating is very necessary to complete themarket and to be some
whether manufacture of a particular part will be profitable or not. Both over and
under estimating are dangerous. Over estimating loads to increase the cost and
tenders may not get suitable response. Under estimating may read to heavy losses
to the concern. Hence accurate estimating is very essential.

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AIMS OF ESTIMATING :-
The main aim of estimating are given bellow:-
1. To the help factory owner's in deciding the manufacturing and selling
policies
2. To help in filling up the tender enquires.
3. To decided about the amount of over heads which helps comparing
and chucking the actual over heads of the factory.
4. To decide the wage rate of worker after working time study
5. It helps to decide a particular part should be purchase from the market as
those to be manufactured.

41
STIMATING PROCEDURE:
1. Production planning department decided the requirements and
specification of production .
2. Production planning department works about drawing lay down the method
and sequences of operation machines to be used, rates allowed to be labour
in consultation with the Time and motion study"
3. department and wages department .
4. To decide accuracy and finish required.
5. To prepare a list of the components of the product.
6. To decide which components can be manufactured in the concern
itself and which should produced from outside.
7. Determine the material cost by calculating the weight of various part
of product.
8. Determine the time required on various operations by using
calculation methods or by time and motion study and adding suitable
allowances.
9. Determine the labour cost considering the wages rate allowed for
various operation and other workers employed for manufacturing
product.
10. Determine the prime cost by adding direct expenses in
the direct material and direct labour cost.
11. Determine the factory over heads including maintenance of plant.
12. Determine the factory over heads considering the policy
of the concern for calculating these expenses.
13. Determine the packing and delivery changes etc.

42
14. Then calculate the total cost in under to fix up the sale price.

15. To decided profit and in the total cost in under to fix up the sale price.
16. To decide discount allowed to distributors.
17. To decide delivery time in consideration with the production
and sales departments.

18. COSTING :-
19. It is determination of on product actual cost of an article. After
20. adding different expenses increased in various department.
21. It may also be define a system which systematically rewards all the
expenditure to determine the cost of manufactured products.

43
 CHAPTER NO 9 CALCULATION AND
SPECIFICATION

Velocity Ratio of Chain Drives:

The velocity ratio of a chain drive is given by
. .= 1 2= 2 1

N1= Speed of rotation of smaller sprocket in

r.p.m., N2= Speed of rotation of larger
sprocket in r.p.m., T1= Number of teeth on
the smaller sprocket, and T2= Number of
teeth on the larger sprocket.
. .= 1 2= 2 1
. .=28/28=1

Experimentally,

Revolution
Revolution of shaft by one push:
Using tachometer, 100 rpm =1.666rps

Torque:
Torque produce in on push: = ×602
=0.148×602 1.666 = 0.851

44
DESIGN SPECIFICATIONS
• SHAFT (DIA)= 6 mm AND 10mm

3. SPROCKET WHEEL AND CHAIN:-

• No of teeth on both sprocket= 28
• Dia of both sprocket= 56 mm
• Length of chain =600 mm
• Optimum centre distance = 215 mm

4. SPRINGS:-
• Diameter of wire = 2mm
• Mean dia of coil = 12 mm
• Free length of spring = 140mm

5. SPUR GEARS:-
• No Of Teeth On Rack = 32
• Rack Length= 220 mm
• No Of Teeth On Pinion = 16
• Diameter Of Pinion Gear =36 mm
• Length of speed breaker=300 mm
• Height of speed breaker=130mm

45
CHAPTER NO 10 COST ESTIMATION

1. MATERIAL COST

Sr No. Part name No. Of Units COST

1 Metal Square tube 2 250

2 Metal Square tube 2 200

3 Metal Square tube 1 50

4 Metal Square tube 2 100

5 Metal strip 2 100

6 Metal strip 2 100

7 Metal Pipe 2 100

8 Spring 2 100

9 6mm Steel rod 2 200

10 10mm Steel rod 2 200

11 Gear 2 400

12 Gear 1 800

13 Sprocket 2 400

14 Bicycle Chain 1 300

15 DC Generator 1 600

16 RACK 1 400

17 Other - 200

TOTAL= 4500

TOTAL COST= 4500

1. LABOUR COST= 500

46
3. OVERHEAD CHARGES
The overhead charges are arrived by “Manufacturing cost”

Manufacturing Cost = Material Cost + Labour cost

= 4500 + 500
= 5000
Overhead Charges = 20% of the manufacturing cost
= 1000
TOTAL COST

Total cost = Material Cost + Labour cost + Overhead Charges

= 4500+500+1000

Total cost for this project = 6000

BREAK EVEN POINT

Let fixed cost (F) =
210000 Variable cost (P)
= 6000 Selling cost (S) =
6300
47
B.E.P = F/(S-P)
=210000/(6300-6000)
= 700 pieces

BREAK EVEN POINT GRAPH

48
 CHAPTER 11
MARKET SURVEY GST
Since GST subsumed indirect taxes of both central government (excise duty
,service tax , custom duty , etc.) and state governments (VAT, Luxury tax , etc),
both the governments now depend on GST for their indirect tax revenue .
Therefore, the GST rate is composed of two rates. Intra-state transaction will
carry one of CGST and one of SGST (in case of state) or CGST and UTGST (in
case of union territory). Therefore, while making an intra- state sale (i.e.,sale
within the same state), the CGST collected will go to the central government and
the SGST collected will go the respective state government in which sale is made
.Similarly, SGST or UTGST are replaced with IGST when intra-state transactions
are involved.

THERE ARE FOUR TYPES OF GST

1.CGST

CGST full form is Central Goods and Service Tax.

CGST refers to the Central GST tax that is levied by the Central Government of
India on any transaction of goods and services tax taking place within a state . It is
one of the two taxes charges on every intra state (with one state ) transaction, the
other one being SGST (or UTGST for Union Territories ) . CGST replace all the
existing Central taxes including Service Tax, Central Excise Duty, CST, Customs
Duty, SAD, etc. The rate of CGST is usually equal to the SGST rate. Both taxes
are charged on the base price of the product. See the example below to understand
it better.
In the example above, when Suresh sales a product to Pradeep in the same state
(Rajasthan), he has to pay two taxes. CGST is for the central government while
SGST is for the state . The rate of CGST is 9 % , same as SGST . After the
application of CGST ( 9 % of Rs 10,000 ) , the final cost of the product will
become Rs 11,800.

49
As you can probably guess, all the taxes in all the conditions above are
borne by the end consumer in the final cost, not by the manufacturer or the
dealer of the product or service. Since GST is levied on consumption, the
state where the product is originally manufactured is not entitled to the tax
collected. If the manufacturing state levies a tax, the same will be transferred
to the consuming state through Central government.

2. SGST

SGST full form is State Goods and Service Tax.

SGST (State GST) is one of the two taxes levied on every intrastate (within
one state) transaction of goods and services. The other one is CGST. SGST
is levied by the state where the goods are being sold/purchased. It will
replace all the existing state taxes including VAT, State Sales Tax,
Entertainment Tax, Luxury Tax, Entry Tax, State Cesses and Surcharges on
any kind of transaction involving goods and services. The State Government
is the sole claimer of the revenue earned under SGST. Let's understand this
with an example.
Suresh from Rajasthan wants to sell some goods to Pradeep in Rajasthan.
The product, originally priced at Rs 10,000 , will attract GST at 18 % rate
comprising of 9 % CGST rate and 9 % SGST rate . The SGST tax amount
here is Rs 900 ( 9 % of Rs 10,000 ) which is fully claimed by the Rajasthan
State Government. The rate of the product after SGST will be Rs 10,900.

3. IGST

IGST full form is Integrated Goods and Service Tax.

Integrated GST (IGST) is applicable on interstate (between two states)
transactions of goods and services, as well as on imports. This tax will be
collected by the Central government and will further be distributed among
the respective states. IGST is charged when a product or service is moved
from one state to another. IGST is in place to ensure that a state has to deal
only with the Union government and not with every state separately to settle

50
the interstate tax amounts. Let's try to understand IGST with an example.
e.g., - Ramesh is a manufacturer in Rajasthan who sold goods worth Rs
10,000 to Suresh in Rajasthan. Since it is an interstate transaction, IGST will
be applicable here. Let's asssume the GST rate is 18 % for the particular
item . So , the IGST amount charged by the Central Government will be Rs
1800 ( 18 % of Rs 10,000 ) , and the refined rate of the product will be Rs
11,800.
Now, GST is a consumption tax that means only the state where the goods
are actually consumed will get the tax benefits, irrespective of the
manufacturing state.

4. UTGST (or UGST)

UTGST full form is Union Territory Goods and Services Tax.

The Union Territory Goods and Services Tax, commonly referred to as
UTGST, is the GST applicable on the goods and services supply that takes
place in any of the five Union Territories of India, including Andaman and
Nicobar Islands, Dadra and Nagar Haveli, Chandigarh, Lakshadweep and
Daman and Diu. This UTGST will be charged in addition to the Central GST
(CGST) explained above. For any transaction of goods/services within a
Union Territory: CGST+ UTGST
The reason why a separate GST was implemented for the Union Territories
is that the common State GST (SGST) cannot be applied in a Union
Territory without legislature. Delhi and Puducherry UTs already have their
own legislatures, so SGST is applicable to them.
1. PRODUCT ANALYSIS:- Product analysis is required to find out
customer's performance for the product. this will be enable the
management to being important that will meet requirement of the
customers. This will be meet requirement of the customers. This will full
fill the present requirements of the market and will be more acceptable
than those of the cometion product.

51
 2. MARKET ANALYSIS :- The object of market analysis is to find the
location of the market. Scopes for sell are product.
3. COMPETITION ANALYSIS: Competition analysis is very much
necessary is very much before the production of product. The product
should full fill all the qualities that is may competition product in the
market.
DISTRIBUTION ANALYSIS :- This consist the study of selling
method of our product . Sales draining distribution of project are studied.

52
 CHAPTER 12
SELECTION OF REGION

Selection of region depends upon the following factors :-

1. PRIMARY FACTORS:-
a. Nearness of market
b. Availability of raw material
c. Availability of labour
d. Transportation facilities
e. Availability of power and fuel
2. SECONDARY FACTORS:-
a. Climate
b. Co- operation of local persons
c. Local restriction and taxes
d. Expansion facilities
e. Availability facilities
f. Safety

53
 CHAPTER 13
SITE SELECTION
Selection of site depends upon following facilities :-
1. Availability of place
2. Availability of workers
3. Availability of power
4. Transportation and communication facilities
5. Nearness of market
6. Availability of water
7. Shaft Safety

Our selected site is near to my district Faizabad and which is near to Ram
Janam Bhumi It iS Situated at main road Lucknow to Gorakhpur It is
situated 300 meter away from main road.

AVAILABLE FACILITIES :-
1. It is 300 meter away from the main road.
2. Electric power house is situated at 8 km. away from our site
hence there is no problem of electrify
3. It is near to Ayodhya Railway Station.
4. Facilities to telecommunication is available nearly
5. For safety of factory police stations situated at a distance of 1
km.
6. Unskilled labour are early available.
7. The facilities of bank are easily available because bank is
situated at a distance of 500 meter from the factory.
8. Out plant is situated on the main road. So there is no
problem of transportation
9. In future for expansion of factory land is easily available.

54
 CHAPTER 14
PLANT LAYOUT

It is define as the machines, equipments and furniture is proper and

suitable sequence (order) for production in minimum fine. getting
maximum time

ADVANTAGE :
1. Utilization of total capacity
2. The efficiency of labour will increase.
3. A good layout of factory minimum the wastage of labour
cost and raw material.
4. Inspection is easy
5. It should proved a better control over all the friction

Plant layout may be of two types

a. Product layout
b. Process layout

PRODUCT LAYOUT :-
In the product layout all the equipments required for one part of product is
grouped together in one department in the sequence of operation performed,
so that pan is complete there. In such type layout only one product is
processed by some line department.
ADVANTAGE :-
1. Less work in process
2. Total material handling cost is loss
3. Lower production time.
4. Less floor area required per unit

55
PROCESS LAYOUT :-
In process layout department is made up of machines, equipments as
process that fall in to one category. According to the friction performed the
product is fetsricated by using department to another according to the
sequence of operation to be performed on it.
ADVANTAGE :-
1. Greater flexibility of production
2. Lower total investment in equipments
3. Better and efficient supervision possible
DESIGN :-Designing is the technique to know the shape, size and
manufacturing of a product.
Elements must be rigid so that the elastic deformation under the applied
forces does not exceed a specified limit.
The machine elements should be sufficient strong rigid and war resistance
with minimum weight and least dimension.

56
 CHAPTER 15
SURVEY OF VILLAGE "RASULAHA" LOCATION

This village is situated at a distance of about 40 Km from "JAUNPUR

CITY RAILWAY STATION". You can go there by bus & Jeep.
MARIYAHU is the nearest railway station. This Village is situated in
JAUNPUR District.
GRAM SAHBA :
Mrs. PUSHPA DEVI is working as the Gram pradhan of this village. He
is educated and well mannered person. All the members of this
Panchayat want to improve the living facilities of this village.

POPULATION:
The population of this village is about 6000. 'HINDUS' are in majority they
are. about 96% Of the total population . Area of this village is about 3 km2
there is a big market on the road There is few Shops of shoes, General
merchant Educational level of this village is very low and about 40% of
total population.

MEANS OF LIVELY HOOD :

The living standard of this village is medium. There main occupation is
agriculture. The main Crop of the Village is rise & wheat. Some people one
also involved in. The land of village is faller land but some far away from
village the land is nice for agriculture. The nature of villagers is very nice.
They are simple living and hard working about 40 to 50 persons of this
village are engaged in government service

57
HEALTH AND HYGIENIC CONDITIONS:
Villagers this village faced very little problem of population due to this the
heath condition of the villagers is almost normal.
The system of drainage is not good for villagers due to these problem
children are often affected from diseases, these the attention is paid toward
head and sanitation. There is one government hospital for treatment two
experienced doctor are sitting there. Some other villagers come to this
hospital for treatment.
There is also a veterinary hospital for treatment of cattle and animals. This
hospital gives a lot of relief to villagers because agriculture is their business
and cattle are very important for their occupation.
Free vaccine provided for villagers and their children from government
hospitals Free vaccine appropriate medicines are also provided for the
cattle of villagers.

EDUCATION :
The education facilities in this village are good in comparison do other ender
developed villages there is facilities of junior high School in this village.
There are four primary school and one junior high school many other
children of neighboring villages are to come here for studies.

THE CAPACITY OF SCHOOL :

The capacity of school are given bellow.

PRIMARY SCHOOL:
Principal- Shri. GYANU

58
PRASAD No of teachers-8
No. of student-200
There are 4 primary school in this area. Total 250 students because some
other children from other villages come here for studies.

JUNIOR HIGH SCHOOL :

Principal-Mr. ACHHAYVAR TIWARI
No. of students- 1000 No. Of teachers-24
In this area there is only one junior high school, Education facilities of these
schools on village are not very good because school the sitting arrangement
and building of school is not good the teachers are very good. They direct
their time for good studies among children. Mr. ACHHAYVAR TIWARI is a
very good principal.

MAIN PROBLEM OF THE VILLAGE :

There are problem which are existing in the villagers. The main problem of
this village is drainage drinking water and unavailability latrines are also
main problem of served villages drainage is the main cause of different
disease like skin cause of disease and visual disease etc.
Mainly the problem of drainage grants from the lack of servers and pipes
drainage problem greed a lot of disease in villager.
The number of tub wells, wells and Hand pump is sufficient but improper
use of water and lack ness of medicines in drinking water. People is
suffering from disease like gout and polio etc. villagers have no idea &
knowledge about their activities which are very harmful for their health like
they do their daily activities in open ground, Besides above problem in
village there are some many problems like-

59
Problem of good
education Problem
of school building
Problem sitting arrangement in
schools Problem of electricity
in village
Problem of seeds and new technology for agriculture.
Railway station is very far from this village. Police station is also situated
in long distance from this village.

ENVIRONMENTAL POLLUTION AND ECOLOGICAL :

DISTURBANCES AND ITS REMEDIES AND WAYS TO MINIMIZE IT

Pollution is the addition or subtraction of some element to or from the

physical sources such as water, air or soil that may change there natural
composition. A chemical substance spore's fungus, Volcanic, gases and other
such similar substances that may change the natural composition of water, air
soil are called pollutants. Over environment is polluted by following factor
1. Air pollution
2. Water pollution
3. Soil pollution
4. Solid pollution
5. Sound pollution
AIR POLLUTION :
The carbon die oxide is related into the air in the form of smoke is related
released into air by burning of fuel

EFFECTS OF AIR POLLUTION :

60
 1. Presence of air Pollution causes loss of atmospheric lazily soiling
of clothes and building.
2. The excess of carbon all oxides in the building.
3. The carbon mono oxide in the atmospheric enters the blood and
hemoglobin
4. Aerorcols causes the excess of ultraviolet rays to increase the
temperature near
WATER POLLUTION :
The ponds, river, lakes and sea are the major sources of water. These sources
get polluted by
1. Domestic sewerage
2. Industrial water
3. Dust
4. Atomic explosion
5. Oil

1. The release of huge quantities of domestic waters the pollution of

major rivers of country.
2. The sewage contains human faces food residue cleaning agents,
detergents, urine etc. eases the water pollution

Pollution is also caused by the water of industries such as lather, sergon bear
wines slaughter houses

EFFECT OF WATER POLLUTION :

1. The increasing concentration of various Chemical in the form of
in organic fertilizers from the crop fields causes different disease
2. The polluted water in the presence of organic substance cubes
the several diseases.
SOIL POLLUTION :
The addition of some organic pollutions in an unidentvied proportion to the
soil system that changes the fertility of soil the main cause of this pollution
is organic compound which one being thrown or soil for heavy fertilization

61
 SOLID WASTE POLLUTION :
Waste product which one being used for as one continuously thrown out
causes unhealthy working and living condition . Water Of different
industries, Bio industries, water of physical Material Passes bad and radio
active properties causes unhealthy living condition .
SOUND POLLUTION :
Sound pollution is very dangerous for every human being because
this pollution effects or causes the mind decay as well as health
decay.
In heavy sound polluted factories worker are getting several diseases like
satirical and other mental disease, Some of the different machines, vibration
of machine speaker used in marriages and sound of automobiles are the
main eases sound pollution is very harmful for human life. Maximum
sound capacity ear is 84 decibel.

62
METHOD TO CONTROL THE ENVIRONMENTAL POLLUTION:

It is essential to have we should stand against of every type pollution because

human being is the main cause of pollution in the next 25 year The increasing
concentration CO2 in air organics in water Radio active in atmosphere and
many other pollutants would increase the temperature and disease. That will
result in unhealthy environment.
To control pollution following steps must be taken
1. Those vehicles should be bound which gives out excessive and
block fumes A punishment of Rs. 500 on that particulars Vehicle
or license of self vehicle must be cancelled out
2. -Factors which Gives out smoke, poisons, should be banned
3. Solid or waste material must be burnt or buried into ground
4. As for as possible be product of factory should be reused
5. These Should be less use of Chemical fertilizers
6. Plantation of the trees should be done in large scale
7. They should be hand rules against cutting the trees
8. Try to reduce consumption of coal, diesel,. Petrol etc.
9. Bio gas plant should be used on a smoke less
10. Cooking gas
Solar cooker and Solar energy should be used as population as energy
source.
All these steps will be applied successfully If we provide combined efforts
and try to keep our atmosphere free from the all pollution

63
SUGGESTION FOR POPULATION CONTROL:

Population explosion is one of the major problems in one country. It

increases such and hence the development of the country goes to nil. This is
mainly due to the lack of literacy and other different factors.
To control the population following suggestion should be given.
1. Adopting literacy programme in the villagers
2. Giving knowledge for the effect of the population over the
development
3. Making effort programme for controlling the population
4. Inspiration the villagers for small family
5. Giving knowledge to villagers about different type of birth control
means
6. Free distribution of birth means like Condom, Mala-D, Copper-T
etc.
7. Inspiring those many who has to children for victims
8. Adopting effective law to check the population explosion
9. Giving preference to those persons who has one or two children

64
VARIOUS PROGRAMME / PROJECT RUNNING FOR THE
DEVELOPMENT & THE PERSONAL AGENCIES INVOLVED
IN THE WORK :
Today government is taking a keen interest in the all round development Of
villages. Agricultural banks and Co-operative society have also been setup
in served village for the good of the farmers. There is office of the block
development officers and the farmers go to the BDO and gets there
problems of the village solved by him television and radio sets have been
installed in Panchayat Ghat.
Post office and seed stores. also have been opened and are helping the
villagers a great deal.

JAWAHAR ROJGAR YOJNA :

This policy of government is running in the villages of adequate opportunity
of jobs for students and villages.
ARRANGEMENTS OF ELECTRICITY :
For the welfare of harijans a number of steps are taken. Electricity
connection its given to them for very normal prices
ANGAN BADI :
The programme 'A ANAGAN BADI' has been started for the education
of old illiterates. Scholarships are also given by governments.
SAHKARI SANGH :
Sakhari Sangh has developed for the problem of villagers. There is only
Sahkari Sangh.

65
 CHAPTER 16

REFERENCE
I. Department of Mechanical Engineering Hewett polytechnic
lucknow
II. A Textbook of Machine Design by R.S.KHURMI AND
J.K.GUPTA.
III. Automobile Engineering , KirpalSingh.
IV. Automobile Engineering,S.M.Pandey& K.K. Shah.
V. www.wikipedia.com.
VI. Shigley Tata McGraw hills (Machine Design).
VII. Generation of Electricity through Speed Breaker Mechanism.
VIII. EVERY SPEED BREAKER IS NOW A SOURCE OF
POWER.

(ASWATHAMAN.V ELECTRONICS AND COMMUNICATION

ENGINEERING SONA COLLEGE OF TECHNOLOGY SALEM,
INDIA). (PRIYADHARSHINI.M ELECTRONICS AND
COMMUNICATION
ENGINEERING SONA COLLEGE OF TECHNOLOGY SALEM,
INDIA

66