DESIGN AND FABRICATION OF POWER

GENERATION BY USING SPEED BRAKER

A PROJECT REPORT

Submitted by

HARUN RASHEETH S.F - 724014114009

MOHAMMED ASHIK.A - 724014114019
MOHAMED ANIF FAZIL S.M - 724014114303
SAHUL HAMEED.J - 724014114304

In partial fulfillment for the award of the degree

Of

BACHELOR OF ENGINEERING

IN

MECHANICAL ENGINEERING
DHAANISH AHMED INSTITUTE OF TECHNOLOGY,
COIMBATORE
ANNA UNIVERSITY: CHENNAI 600 025
APRIL 2017
 BONAFIDE CERTIFICATE

Certified that this project report “DESIGN AND FABRICATIONOF

POWER GENERATION FROM SPEED BRAKER” is the bonafidework of
“HARUN RASEETH.S.F, MOHAMED ASHIK.A, MOHAMED ANIF
FAZIL.S.M, SAHUL HAMEED.J ” who carried out the project work under my
supervision.

SIGNATURE SIGNATURE

Mr.S.Boopathi Joe Kamal raj ME, (Ph.D) Mr.Thirugnanasampantham.N , ME.

HEAD OF THE DEPARTMENT SUPERVISOR
Assistant Professor
Department of Mechanical Engineering Department of Mechanical Engineering
Dhaanish Ahmed Institute of Technology Dhaanish Ahmed Institute of Technology
Coimbatore-641 105 Coimbatore-641 105

INTERNAL___________________ EXTERNAL____________________
 ACKNOWLEDGEMENT

The success of any project depends largely on the people associated with
it. We are indebted to everyone who has made valuable contribution towards
the success of this project. I would also like to take the opportunity to
acknowledge the enthusiasm of all these personalities.

We would like to extend our gratitude to Dr.S.NANDHAKUMAR,

M.E, Ph.D, Principal, Dhaanish Ahmed Institute of Technology, Coimbatore,
who has encouraged us in letting more and more success in our engineering.

We also wish to convey our sincere thanks to MR.S.BOOPATHI JOE

KAMAL RAJ, M.E, (Ph.D) Head of the Department, Mechanical Engineering
for his encouragement and support towards this project.

We like to thank our project guide MR.N.THIRUGNANASAMPANTHAM,

M.E, Assistant professor, Department of Mechanical Engineering for
providing us the technical support to improve our skills during presentation and
for their guidance.

We like to express our thanks to all teaching and non-teaching staff

members in the Department of Mechanical Engineering and also like to
express our thanks to all those who helped us for the successful completion of
this project.
 ABSTRACT

This project harvests energy from speed breaker by making gear

arrangement and using electronic gadgets. Large amount of electricity can be
generated saving lot of money. And if implemented will be very beneficial for
government. When vehicle is in motion it produce various form of energy like, due
to friction between vehicles wheel and road i.e. rough surface heat energy is
produced, also when vehicle traveling at high speed strikes the wind. The
principles involved kinetic energy to electrical energy conversion.
There is a system to generate power by converting the kinetic energy
generated by a vehicle going upon a speed breaker into electrical energy. When the
vehicle is moves on speed breaker producing a kinetic energy due to the load of
vehicle its contact to the surface plate. This surface plate move downward due to
load of vehicle by the suspension spring. This surface plate pressing in vertical rod
end having bevel gear mechanism. The vertical upward and downward motion
convert in to rotation motion by the uptain bevel gear motion. The rotational
motion contacted in to the dynamo by using chain drive. The power is transmit
from mechanical energy. Then dynamo converted in to mechanical energy to
electrical energy.
 TABLE OF CONTENTS

CHAPTER TITLE PAGE

NO NO
ABSTRACT i
LIST OF FIGURES ii
LIST OF SYMBOLS AND ABBREVATIONS iv
1 INTRDUCTION 1-3

1.1 General 1
1.2 Alternative method 2
2 LITERATURE REVIEW 5-6
2.1 A Novel Speed-Breaker for Electrical
Energy Generation Suitable forElimination of Remote 5
Parts of Power Systems where is Near to Roads

2.2 Development of speed breaker device for

generation of compressed air on highways in remote 5
areas
2.3 Power Generation Using Speed Breaker with
Auto Street Light 6
3 OVERVIEW 7-13
3.1 Working Principle 7
3.1.1 Mechanical to Electrical Energy 8
3.2 Construction & Operation 11
3.4 Components Used 12
3.5 Circuit Working 13
4 CONSTRUCTION DETAILS 14-39
4.1 Dynamo 14
4.2 Faraday Principle 15
4.3 Jedlik’s Dynamo 16
4.4 Gramme Dynamo 16
4.5 Terminology 17
4.6 Equivalent Circuit 18
4.7 Maximum Power 19
4.8 Roller 19
4.9 Microcontroller 21
4.10 Photodiode 24
4.11 Led 25
4.12 IC 555 timer 26
4.13 Monostable Multivibrater using 555 timer 28
4.14 Definition of pin function 28
4.15 Transistors 33
4.16 Symbols for Transistors 33
4.17 Biasing of Transistor 34
4.18 Circuit Configurations 34
4.19 Diode 35
4.20 Temperature Dependence of v-i characteristic 36
4.21 Resistance 36
4.22 Capacitor 36
4.22.1 Ceramic capacitor 37
4.22.2 Electrolytic capacitor 37
4.23 Integrated circuit 38
5 FUTURE SCOPE 40-42
5.1 Stepper Motor 41
5.2 Open loop versus closed loop commutation 41
5.3 Types 42
5.4 Two phase stepper motor 42
5.4.1 Unipolar motors 42
6 CONCLUSION 43
REFERENCE 44
 LIST OF FIGURE

SI.NO TITLE PG.NO

1. Fig 1.1 Roller Mechanisms during
Electricity Generation from Speed Breaker 3
2. Fig 1.2 Rack And Pinion Mechanism for Electricity
Generation from Speed Breaker 3
3. Fig 2.1 General Idea of Installation of
Dynamo Motor 5
4. Fig 2.2 Rechargeable Battery 6
5. Fig 2.3 General Block Diagram 7
6. Fig 2.4 Connection through IC 555 8
7. Fig 2.5 General Layout 9
8. Fig 3.1 Portable Generator Side View Showing
Gasoline Engine. 14
9. Fig 3.2 Jedlik's Dynamo 15
10. Fig 3.3 Equivalent Circuit of Generator and Load 17
11. Fig 3.4 Roller 19
12. Fig 3.5 Microcontroller 21
13. Fig 3.6 Photodiode 23
14. Fig 3.7 Light Emitting Diode 24
15. Fig 3.8 NE555 Timer Block Diagram 25
16. Fig 3.9 NE555 Timer Pin Description 25
17. Fig 3.10 555 Timer Tester 30
18. Fig 3.11 Structure and Symbol of P-N-P Transistor 31
19. Fig 3.12 (A) P-N-P Transistor Biasing (B) N-P-N
Transistor Biasing 32
20. Fig 3.13 Volt-Ampere Characteristics of a P-N Diode 33
21. Fig 3.14 Resistance 34
22. Fig 3.15 Tabular and Disc Type Ceramic Capacitors 35
23. Fig 3.16 Electrolytic and Tantalum Capacitor 36
24. Fig 3.17 Integrated Circuit 36
 LIST OF SYMBOLS AND ABBREVIATIONS

LDR - Light Diode Resistance

LED - Light Emitting Diode
NiCd- Nickel Cadmium
NiMH- Nickel Metal Hydride
Li-ion- Lithium ion
DC- Direct Current
EMF- Electromagnetic field
AME- Advanced Machine and Engineering Co.
ROM- Read Only Memory
RAM- Random Access Memory
CPU- Central Processing Unit
DSP- Digital Signal Processing
MPLAB- Microproessor lab
UV- Ultraviolet
TTL- Transistor transistor logic
 CHAPTER 1

INTRODUCTION

1.1GENERAL

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. We connect one
mechanical rod with the dynamo and fit this rod on the surface of the road. When
any vehicle moves from this roller then due to friction, vehicle Rotate the rod or
roller and roller then move the dynamo. When dynamo move then it generates a
voltage and this voltage now connects to the bulbs. In actual practice with the help
of this voltage we will charge the battery and then we use this voltage to light the
small bulb.

The second part of this project is an efficient use of energy by using

simple electronics. We always see that road light continuously glow whether
vehicle on path or not. We have introduced a concept to avoid a waste of light. We
have used two sensors between some distances. When vehicle pass through first
sensor it sends the signal to the microcontroller that the vehicle is passing along in
that particular distance then light will glow for that particular time and when
vehicle goes out from the second sensor then the second sensor sends a signal to a
microcontroller that vehicle has been passed through that particular path then light
gets off automatically. Different types of basic electronics components has been
used to get the desired output like capacitor, resistor etc.

We have also used a light diode resistance(LDR) when LDR senses a

light around it, all the road lights gets OFF and when LDR senses that it is dark
around it, then LDR sends a signal to microcontroller then all the road lights gets
ON. By using a LDR we can avoid a waste of light that glow in a day time. The
two sensors are made from the concept of electronics. These sensors are called an
infrared sensor which is made from photo diode and light emitting diode each.
When any vehicle pass from first sensor then first sensor becomes ON, for that
time and the road lights gets ON and when it pass from second sensor the second
sensor become ON and the first sensor gets OFF then the road light gets OFF.

1.2.ALTERNATIVE METHOD
In power generation using speed breaker, we can use different
mechanism to convert the mechanical energy into the electrical energy from the
speed breaker. The generation of electricity using the vehicle weight can considers
as an input. The possible three different mechanisms are given below:
 Crank-shaft mechanism
 Roller mechanism
 Rack and pinion mechanism
In that project we have introduced a roller mechanism to convert the
mechanical energy into the electrical energy. In a roller mechanism the
maintenance is required of the high level. Material selection is also an important
task for the roller type mechanism. The below figure 1.1 shows the basic
mechanism of roller type. In that one roller is linked with chain to the shaft of a
dynamo, when vehicle moves over a speed breaker then potential energy is
converted into a rotational energy which rotates the shaft of a dynamo due to that
electricity is generated.

Fig 1.1 Roller mechanism during electricity generation from speed

breaker.

By using a crank shaft mechanism we can also generate an electrical power

from mechanical power. Crank shaft are required to be mounted on bearings which
creates a balancing problems in that mechanism which leads a problem of
mechanical vibration which in turn can damage a bearings.
The third and last mechanism is a rack and pinion mechanism. This
mechanism is most efficient mechanism in comparison of the other two. Maximum
gear losses which occur in that mechanism can lie between three to five percent
and efficiency of that mechanism can lie between ninety to ninety five percent. Fig
1.2 shows the basic concept of rack and pinion mechanism.
 CHAPTER 2

LITERATURE REVIEW

2.1 A Novel Speed-Breaker for Electrical Energy Generation Suitable for

Elimination of Remote Parts of Power Systems where is Near to Roads
•Mohsen Partodezfoli1, Abbas Rezaey1, Zahra Baniasad1,
HoriehRezaey11Department of Electrical and Computer Engineering, Islamic
Azad University, South Tehran Branch, Tehran, Iran
•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.

2.2 Development of speed breaker device for generation of compressed air on

highways in remote areas

•Ashok Kumar Sharma1, OmkarTrivedi2, UmeshAmberiya2, VikasSharma2

Associate Professor, Department of Mechanical Engineering, YIT, Jaipur, India
Student, Department of Mechanical Engineering, YIT, Jaipur, India

•Roads and highways in India are provided with speed breaker to control the speed
of traffic in congested areas. This energy loss on speed breakers can be utilized for
useful purposes. This paper describes the potential of such type of energy available
on roads and its utilization for useful work. The stages of development of a speed
breaker device are described and the mechanism to generate and store compressed
air that can be further used for desired purpose is elaborated.
2.3 Power Generation Using Speed Breaker with Auto Street Light

•AmanpreetKaur1, ShivanshKumar Singh2, Rajneesh3, Parwez4,

Shashank5 AP, EIE Dept, GalgotiasCollege of Engineering and
Technology, Gr. Noida, U.P1 Student, EIE Dept, GalgotiasCollege of
Engineering and Technology, Gr. Noida, U.P

•The energy crisis is any 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 is basic physics, to convert the
kinetic energy into electrical energy that gone wasted when the vehicle
runs over speed-breaker. Since then, a lot has been done in this field.
 CHAPTER 3

OVERVIEW

3.1 WORKING PRINCIPLE

3.1.1 MECHANICAL TO ELECTRICAL ENERGY

One rod with the dynamo is placed like a speed breaker. Dynamo means a
generator that produces direct current with the use of a commutator. The dynamo
uses rotating coils of wire and magnetic fields to convert mechanical rotation into a
pulsing direct electric current through Faraday's law. A dynamo machine consists
of a stationary structure, called the stator, which provides a constant magnetic
field, and a set of rotating windings called the armature which turn within that
field. Movement of vehicle just rotates the dynamo shaft and electricity is
generated. This voltage is to be stored in the chargeable battery.
In the night lights are automatic on with the help of photovoltaic switch
logic. But all lights are not on, only half light are on. Other half lights switch on
automatically when any vehicle move on the bridge, when there is no vehicle on
the bridge then lights are off automatically. We use two infrared sensors’ to check
the movement of vehicle. When first infra red sensor is on then lights are on and
when second sensor is interrupting then lights are off.A Street
light, lamppost, street lamp, light standard, or lamp standard is a raised source
of light on the edge of a road, which is turned on or lit at a certain time every night.
Major advantages of street lighting includes: prevention of accidents and
increase in safety. Studies have shown that darkness results in a large number of
crashes and fatalities, especially those involving pedestrians; pedestrian fatalities
are 3 to 6.75 times more vulnerable in the dark than in daylight. Street lighting has
been found to reduce pedestrian crashes by approximately half percent.

3.2 CONSTRUCTION & OPERATION:

Fig 3.1 General idea of installation of dynamo motor

In this model we show that how we generate a voltage from the busy road
traffic. In all the city’s traffic is very much high and on some road, traffic move
like a tortoise. If we employ a speed breaker type generator on the road then we
utilize the friction of vehicle into mechanical energy and then this mechanical
energy is further converted into electrical energy with the help of the powerful
dynamo. So we install a one powerful dynamo on the road.
 In actual practice we use this dynamo to generate a voltage and after
generating a voltage we charge the battery. When battery is fully charged then we
use this battery as a storage device.

Fig 3.3 general block diagram

 Fig 3.5 General Layout

In this project we show that how we use IC 555 as a automatic street light
function. Here in this project IC 555 work as a monostable timer. Pin no 4 and 8 of
the IC is connected to the positive supply. Pin no 1 of the IC is connected to the
ground pin. Pin no 3 is the output pin. On this pin we connect a output L.E.D.
LDR is connected to the pin no 2 of the IC via 100 k ohmresistor. When light fall
on the LDR then LDR offers a low resistance. When LDR is in dark then LDR
offers a high resistance. When we convert the LDR by hand then LDR resistance
become high and so pin no 2 become more negative. When pin no 2 become
negative then IC 555 triggers itself and output is on. This is the function of the
monostable timer.

3.3 MATERIAL REQUIRED

After the general layout of the speed breaker system has been made of
successful working it is necessary to select proper material for the system of
refrigeration. This involves the consideration of many facts about available
material such as dynamo weight, size shape of the component material cost,
fabrication cost, overhead charges and many other properties peculiar to the use of
which to member is to be fitted.

The following four types of principle properties of material effect their

selection.
1. Mechanical
2. Physical
3. Chemical
4. Form manufacturing point of view

It is important that the material to be used in such a way as to take full

advantage of their natural characteristics following material is selected for the
fabrication of speed breaker by road. The roller which is extensively used in speed
breaker to generate a electricity are made from a materials like synthetic rubber,
rumble strips etc for a low weight vehicles and medium weight vehicles like bikes,
scooters, bicycles, auto rickshaw, cabs etc

3.4 COMPONENTS USED

1. 89S51 Microcontroller
2. Photodiode (2)5MM
3. Infra Red Led (2)5MM
4. 7805 Regulator (5 VOLT)
5. Crystal (12 MHZ) Connected to pin no 18 and 19
27 PF (2) Grounded from crystal
 Resistance
10K OHM (3)
470 OHM (2)
270 OHM (6)
1 K OHM (1)
 Ldr for automatic street light
NPN BC 548 for LDR switching
 Requirement of PCB
12 volt dynamo
6 volt chargeable battery
Changover switch
L.E.D (6) for street light
3.5 CIRCUIT WORKING

In this project we use 89S51 controller, family member of the

8051 family. Supply voltage of the microcontroller is 5 volt dc. For this purpose
we convert the battery voltage into 5 volt dc with the help of the 5 volt regulator
circuit. For this purpose we use IC 7805 regulator to regulate the high voltage into
5 volt dc. One capacitor is ground from the regulator for filtration.

Capacitor reduces the noise. Output of the regulator is connected to the pin no40 of
the controller directly. One crystal is connected to the pin no 18 and 19 of the
controller to provide an oscillation signal. For this purpose we use 12 MHz crystal.
Two capacitor are grounded from the crystal to reduce the noise. In this project we
use two logic. One is light sensitive logic and second is road sensor logic.
When sensor is in dark then all the lights are on and when sensor is in light then all
the lights are off. This is done by the light sensor (LDR). LDR is a light dependent
resistor, when light fall on the LDR then LDR offers a low resistance and when
LDR is in dark then LDR offers a high resistance. Here in this project we use the
LDR with npn transistor circuit. Emitter of the npn transistor is connected to the
ground and collector is connected to the pin no 3 of the controller.
 CHAPTER 4

CONSTRCTION DETAILS

4.1 DYANAMO

Dynamo uses rotating coils of wire and magnetic fields to convert

mechanical rotation into a pulsing direct electric current through Faraday's law. A
dynamo machine consists of a stationary structure, called the stator, which
provides a constant magnetic field, and a set of rotating windings called
the armature which turn within that field. On small machines the constant magnetic
field may be provided by one or more permanent magnets; larger machines have
the constant magnetic field provided by one or more electromagnets, which are
usually called field current.

The commutator was needed to produce direct current. When a loop of wire
rotates in a magnetic field, the potential induced in it reverses with each half turn,
generating an alternating current. However, in the early days of electric
experimentation, alternating current generally had no known use. The few uses for
electricity, such as electroplating, used direct current provided by messy
liquid batteries. Dynamos were invented as a replacement for batteries. The
commutator is a set of contacts mounted on the machine's shaft, which reverses the
connection of the windings to the external circuit when the potential reverses, so
instead of alternating current, a pulsing direct current is produ
4.2 FARADAY PRINCIPLE

In 1831-1832Michael Faraday discovered that a potential difference is

generated between the ends of an electrical conductor that moves perpendicular to
a magnetic field. He also built the first electromagnetic generator called the
'Faraday disc',

A type of homopolar generator, using a copper disc rotating between the

poles of a horseshoe magnet. It produced a small DC voltage, and large amounts of
current. The first dynamo based on Faraday's principles was built in 1832 by
HippolytePixii, a French instrument maker. It used a permanent magnet which was
rotated by a crank.

Unlike the Faraday disc, many turns of wire connected in series can be used
in the moving windings of a dynamo. This allows the terminal voltage of the
machine to be higher than a disc can produce, so that electrical energy can be
delivered at a convenient voltage.

The relationship between mechanical rotation and electric current in a

dynamo is reversible; the principles of the electric motor were discovered when it
was found that one dynamo could cause a second interconnected dynamo to rotate
if current was fed through it.
4.3 JEDLIK’S DYMAMO

Fig 4.2 Jedlik's dynamo

In 1827, AnyosJedlik started experimenting with electromagnetic rotating

devices which he called electromagnetic self-rotors. In the prototype of the single-
pole electric starter (finished between 1852 and 1854) both the stationary and the
revolving parts were electromagnetic. He formulated the concept of the dynamo at
least 6 years before Siemens and Wheatstone. In essence the concept is that instead
of permanent magnets, two electromagnets opposite to each other induce the
magnetic field around the rotor.

4.4 GRAMME DYNAMO

Both of these designs suffered from a similar problem: they induced

"spikes" of current followed by none at all. Antonio Pacinotti, an Italian scientist,
fixed this by replacing the spinning coil with a toroidal one, which he created by
wrapping an iron ring. This meant that some part of the coil was continually
passing by the magnets, smoothing out the current. ZénobeGramme reinvented this
design a few years later when designing the first commercial power plants, which
operated in Paris in the 1870s. His design is now known as the Gramme dynamo.
Various versions and improvements have been made since then, but the basic
concept of a spinning endless loop of wire remains at the heart of all modern
dynamos.
Other types of electrical generator exist, based on other electrical
phenomena such as piezoelectricity, and magneto hydro-dynamics. The
construction of a dynamo is similar to that of an electric motor, and all common
types of dynamos could work as motors.

4.5 TERMINOLOGY

The parts of a dynamo or related equipment can be expressed in either

mechanical terms or electrical terms. Although distinctly separate, these two sets of
terminology are frequently used interchangeably or in combinations that include
one mechanical term and one electrical term. This causes great confusion when
working with compound machines such as a brushless alternator or when
conversing with people who are used to working on a machine that is configured
differently than the machines that the speaker is used to.
 Mechanical
 Rotor: The rotating part of an alternator, generator, dynamo or motor.
 Stator: The stationary part of an alternator, generator, dynamo or motor.
 Electrical
 Armature: The power-producing component of an alternator, generator,
dynamo or motor. The armature can be on either the rotor or the stator.
4.6 EQUIVALENT CIRCUIT

Fig 4.3 Equivalent circuit of generator and load

G = generator
VG=generator open-circuit voltage
RG=generator internal resistance
VL=generator on-load voltage
RL=load resistance
1

 Before starting the generator, measure the resistance across its terminals
using an ohmmeter. This is its DC internal resistance RGDC.
 Start the generator. Before connecting the load RL, measure the voltage
across the generator's terminals. This is the open-circuit voltage VG.
 Connect the load as shown in the diagram, and measure the voltage across it
with the generator running. This is the on-load voltage VL.
 Measure the load resistance RL, if you don't already know it.
4.7 MAXMIMUM POWER

The maximum power theorem applies to generators as it does to any

source of electrical energy. This theorem states that the maximum power can be
obtained from the generator by making the resistance of the load equal to that of
the generator. However, under this condition the power transfer efficiency is only
50%, which means that half the power generated is wasted as heat and Lorentz
force or back emf inside the generator. For this reason, practical generators are not
usually designed to operate at maximum power output, but at a lower power output
where efficiency is greater.

4.8 ROLLER

Suited for where heavy loads must be moved in confined spaces without
loss of precision or rigidity, Tschudin and Heid linear roller cages and guides
allows displacement of moving parts in axial direction via use of parallel shafts and
sleeves; no radial movement is possible. Rollers offer line contact with guide,
enabling low pre-load at assembly to be maintained. Rollers are arranged within
plastic or metallic cage in spiral fashion, spread over entire surface area of shaft
and sleeve.

Tschudin&Heid linear roller cages and guides are components for

machine, instrument, tool and fixture applications. The novel design of the rollers
and cages allows the displacement of moving parts in an axial direction through the
use of parallel shafts and sleeves. No radial movement is possible. This novel
construction is particularly appropriate in cases where heavy loads must be moved
in confined spaces without loss of precision or rigidity. The use of special "rollers"
instead of balls results in line contact with the guide rather than point contact as
with ball-type guides. Because of this line contact, pre-load at assembly can be
kept low, which produces a low surface pressure between the rollers and guides. In
spite of this, the bearing is rigid, accurate and can be heavily loaded. The rollers
are arranged within a plastic or metallic cage in spiral fashion, spread over the
entire surface area of the shaft and sleeve, leading to a longer service life of the
guide unit.
This is also a low maintenance unit, requiring only a thin lubricating
film for normal operation. Complete cylinder linear guides, comprising shaft and
sleeve with matched roller cage can be supplied ready for fitting to customer's
specifications.
Advanced Machine & Engineering Co., is a manufacturer located in
Rockford, Ill., serving the Machine Tool Industry with precision components and
accessories, including spindle interface components, work holding devices, and,
through our sister company, Hennig, machine enclosures, chip removal and
filtration systems. The Fluid Power - Safety markets are served with cylinder rod
locks and safety catcher devices; and the Production Saw market with our Am Saw
carbide saw machines and Speed cut blade products. AME has manufacturing
partners and customers around the world.
 Fig 4.4 Roller

Henning, Inc. designs and produces custom machine protection and

chip/coolant management products for state-of-the-art machine tools. Henning
products are designed to protect against corrosion, debris and common workplace
contaminants. Manufacturing facilities are located in the U.S., Germany, Brazil,
India, Japan, China and South Korea. Repair centers are located in Machesney
Park, IL; Chandler, OK; Livonia, MI; Blue Ash, OH; Mexico City, Mexico; and
Saltillo, Mexico.

4.9 MICROCONTROLLER

A microcontroller is a small computer on a single integrated circuit

containing processorcore ,memory, and programmable input/output peripherals.
Program memory in the form of NOR flash or OTP ROM is also often included on
chip, as well as a typically small amount of RAM. Microcontrollers are designed
for embedded applications, in contrast to the microprocessors used in personal
computers or other general purpose applications.
 Microcontrollers are used in automatically controlled products and devices,
such as automobile engine control systems, implantable medical devices, remote
controls, office machines, appliances, power tools, and toys. By reducing the size
and cost compared to a design that uses a separate microprocessor, memory, and
input/output devices, microcontrollers make it economical to digitally control even
more devices and processes. Mixed signal microcontrollers are common,
integrating analog components needed to control non-digital electronic systems.
Some microcontrollers may use four-bit words and operate at clock
rate frequencies as low as 4 kHz, for low power consumption (mill watts or
microwatts). They will generally have the ability to retain functionality while
waiting for an event such as a button press or other interrupt; power consumption
while sleeping (CPU clock and most peripherals off) may be just nanowatts,
making many of them well suited for long lasting battery applications.

These languages are either designed especially for the purpose, or versions
of general purpose languages such as the C programming language. Compilers for
general purpose languages will typically have some restrictions as well as
enhancements to better support the unique characteristics of microcontrollers.
Some microcontrollers have environments to aid developing certain types of
applications. Microcontroller vendors often make tools freely available to make it
easier to adopt their hardwareher clock speeds and power consumption.
 Fig 4.5 Microcontroller

Many microcontrollers are so quirky that they effectively require their own
non-standard dialects of C, such as SDCC for the 8051, which prevent using
standard tools (such as code libraries or static analysis tools) even for code
unrelated to hardware features.
Interpreter firmware is also available for some microcontrollers. For
example, BASIC on the early microcontrollers Intel 8052; BASIC and FORTH on
the Zilog Z8 as well as some modern devices.
Simulators are available for some microcontrollers, such as in
Microchip's MPLAB environment. These allow a developer to analyze what the
behavior of the microcontroller and their program should be if they were using the
actual part. A simulator will show the internal processor state and also that of the
outputs, as well as allowing input signals to be generated. While on the one hand
most simulators will be limited from being unable to simulate much other
hardware in a system, they can exercise conditions that may otherwise be hard to
reproduce at will in the physical implementation, and can be the quickest way to
debug and analyze problems.

4.10 PHOTODIODE

A photodiode is a type of photo detector capable of converting light into

either current or voltage, depending upon the mode of operation.
Photodiodes are similar to regular semiconductor diodes except that they may be
either exposed (to detect vacuum UV or X-rays) or packaged with a window
or optical fiber connection to allow light to reach the sensitive part of the device.
Many diodes designed for use specifically as a photodiode will also use a PIN
junction rather than the typical PN junction.
A photodiode is a PN junction or PIN structure. When a photon of sufficient
energy strikes the diode, it excites an electron, thereby creating a mobile electron
and a positively charged electron hole. If the absorption occurs in the junction's
depletion region, or one diffusion length away from it, these carriers are swept
from the junction by the built-in field of the depletion region. Thus holes move
toward the anode, and electrons toward the cathode, and a photocurrent is
produced.
When used in zero bias or photovoltaic mode, the flow of photocurrent out
of the device is restricted and a voltage builds up. The diode becomes forward
biased and "dark current" begins to flow across the junction in the direction
opposite to the photocurrent. This mode is responsible for the photovoltaic effect,
which is the basis for solar cells—in fact, a solar cell is just a large area
photodiode.
 Fig 4.6 Photodiode

In this mode the diode is often reverse biased, dramatically reducing the
response time at the expense of increased noise. This increases the width of the
depletion layer, which decreases the junction's capacitance resulting in faster
response times. The reverse bias induces only a small amount of current (known as
saturation or back current) along its direction while the photocurrent remains
virtually the same.
Although this mode is faster, the photoconductive mode tends to
exhibit more electronic noise. The leakage current of a good PIN diode is so low (<
1nA) that the Johnson–Nyquist noise of the load resistance in a typical circuit often
dominates.

4.11 LED

A light-emitting diode (LED) is a semiconductor device that emits

incoherent narrow-spectrum light when electrically biased in the forward direction
of the P-n junction. This effect is a form of electroluminescence. LEDs are small
extended sources with extra optics added to the chip, which emit a complex
intensity spatial distribution. The color of the emitted light depends on the
composition and condition of the semi conducting material used, and can be
infrared, visible or near-ultraviolet.

Fig 4.7 Light emitting diode

The kinetic energy of the wheel gets converted in to electrical energy by the
help of generator. This electrical energy is shown by LED.

4.12 IC 555 TIMER

IC555 timer available in 8 pin DIP or To-99 Package is one of the most
popular and versatile sequential logic devices which can be used in monostable and
a stable mode its inputs and outputs are directly compatible both TT 1 and CMOS
logic circuit. The functional diagram of 555 timer is shown in fig. On a negative
going excursion of the trigger input when the trigger input passes through the
reference voltage VCC/3, the output of the comparator 2 goes high and sets the flip-
flip (-1). On a resistive going excursion of the threshold input, the output of a
comparator 1 goes high when the threshold voltage passes through the reference
voltage 2VCC/3. This reset the flip-flop ( = 1). The flip flop is cleared when the
reset input is less than about 0.4V. When this input is not required to be used it is
normally return to Vcc.
 An extend timing capacitor C is to be connected between the
dischargeterminal and ground. When the flip flop is in the reset state, its  = 1.
This drives T1 to situation thereby discharging the timing capacitor. The timing
cycles starts when the flip flop goes to set state and therefore T1 is off. The timing
capacitor charges with the time constant T=RA. Where C is the timing capacitor
and RA is an external resistor to be connected between the discharge terminal and
Vcc.

Fig 4.8 NE555 Timer Block Diagram

 The output is at logic 1 whenever the transistor T1s off and at logic 0 T1 is
on. The load can be connected either between the output terminal and V cc or
between the output and ground terminals. The voltage corresponding to high
output is approximately 0-5V below Vcc and for low is approximately 0.1V.

4.13 MONOSTABLE MULTIVIBRATER USING 555 TIMER

A monostablemultivibrator circuit using a 555 timer is shown in fig. If the

trigger input is held high, then order steady – state condition the transistor T1 is on
the discharge and output terminal are at low level it can be verified that T 1can not
be off under steady state condition. When negative pulse applied at trigger input
across the voltage Vcc/3 the output of comparator 2 goes high which sets the flip
flop and consequently. T1 turn off and output goes high. The capacitor C starts
getting charged to Vcc with timer constant (T = RA.C).

4.14 DEFINITION OF PIN FUNCTION

Pin 1 (Ground): The ground (or common) pin is the most-negative supply
potential of the device, which is normally connected to circuit common (ground)
when operated from positive supply voltages.
Pin 2 (Trigger): This pin is the input to the lower comparator and is used to
set the latch, which in turn causes the output to go high. This is the beginning of
the timing sequence in monostable operation. Triggering is accomplished by taking
the pin from above to below a voltage level of 1/3 V+ (or, in general, one-half the
voltage appearing at pin 5). The action of the trigger input is level-sensitive,The
trigger pulse must be of shorter duration than the time interval determined by the
external R and C. If this pin is held low longer than that, the output will remain
high until the trigger input is driven high again. One precaution that should be
observed with the trigger input signal is that it must not remain lower than 1/3 V+
for a period of time longer than the timing cycle. If this is allowed to happen, the
timer will re-trigger itself upon termination of the first output pulse.A second
precaution with respect to the trigger input concerns storage time in the lower
comparator. This portion of the circuit can exhibit normal turn-off delays of several
microseconds after triggering; that is, the latch can still have a trigger input for this
period of time after the trigger pulse. In practice, this means the minimum
monostable output pulse width should be in the order of 10uS to prevent possible
double triggering due to this effect. The voltage range that can safely be applied to
the trigger pin is between V+ and ground. A dc current, termed the trigger current,
must also flow from this terminal into the external circuit. This current is typically
500nA (nano-amp) and will define the upper limit of resistance allowable from pin
2 to ground. For an actable configuration operating at V+ = 5 volts, this resistance
is 3 Mega-ohm; it can be greater for higher V+ levels.
Pin 3 (Output): The output of the 555 comes from a high-current totem-
pole stage made up of transistors Q20 - Q24. Transistors Q21 and Q22 provide
drive for source-type loads, and their Darlington connection provides a high-state
output voltage about 1.7 volts less than the V+ supply level used. Transistor Q24
provides current-sinking capability for low-state loads referred to V+ (such as
typical TTL inputs). Transistor Q24 has a low saturation voltage, which allows it to
interface directly, with good noise margin, when driving current-sinking logic.
Exact output saturation levels vary markedly with supply voltage, however, for
both high and low states. High-state level is typically 3.3 volts at V+ = 5 volts;
13.3 volts at V+ = 15 volts. Both the rise and fall times of the output waveform are
quite fast, typical switching times being 100nS. The state of the output pin will
always reflect the inverse of the logic state of the latch, and this fact may be seen
by examining Fig 3.8. Since the latch itself is not directly accessible, this
relationship may be best explained in terms of latch-input trigger conditions. To
trigger the output to a high condition, the trigger input is momentarily taken from a
higher to a lower level.

Pin 4 (Reset): This pin is also used to reset the latch and return the output
to a low state. The reset voltage threshold level is 0.7 volt, and a sink current of
0.1mA from this pin is required to reset the device. These levels are relatively
independent of operating V+ level; thus the reset input is TTL compatible for any
supply voltage. The reset input is an overriding function; that is, it will force the
output to a low state regardless of the state of either of the other inputs. It may thus
be used to terminate an output pulse prematurely, to gate oscillations from "on" to
"off", etc. Delay time from reset to output is typically on the order of 0.5 µS, and
the minimum reset pulse width is 0.5 µS. Neither of these figures is guaranteed,
however, and may vary from one manufacturer to another. In short, the reset pin is
used to reset the flip-flop that controls the state of output pin 3. The pin is activated
when a voltage level anywhere between 0 and 0.4 volt is applied to the pin.

Pin 5 (Control Voltage): This pin allows direct access to the 2/3 V+
voltage-divider point, the reference level for the upper comparator. It also allows
indirect access to the lower comparator, as there is a 2:1 divider (R8 - R9) from
this point to the lower-comparator reference input, Q13. Use of this terminal is the
option of the user, but it does allow extreme flexibility by permitting modification
of the timing period, resetting of the comparator, etc. When the 555 timer is used
in a voltage-controlled mode, its voltage-controlled operation ranges from about 1
volt less than V+ down to within 2 volts of ground (although this is not
guaranteed). Voltages can be safely applied outside these limits, but they should be
confined within the limits of V+ and ground for reliability.The control voltage may
be varied from 45 to 90% of the Vcc in the monostable mode, making it possible to
control the width of the output pulse independently of RC. Varying the voltage in
the astable mode will produce a frequency modulated (FM) output.

Pin 6 (Threshold): Pin 6 is one input to the upper comparator (the other
being pin 5) and is used to reset the latch, which causes the output to go low.
Resetting via this terminal is accomplished by taking the terminal from below to
above a voltage level of 2/3 V+ (the normal voltage on pin 5). The action of the
threshold pin is level sensitive, allowing slow rate-of-change waveforms. The
voltage range that can safely be applied to the threshold pin is between V+ and
ground. A dc current, termed the threshold current, must also flow into this
terminal from the external circuit. This current is typically 0.1µA, and will define
the upper limit of total resistance allowable from pin 6 to V+. For either timing
configuration operating at V+ = 5 volts, this resistance is 16 Mega-ohm. For 15
volt operation, the maximum value of resistance is 20 MegaOhms.
Pin 7 (Discharge): This pin is connected to the open collector of anpn
transistor (Q14), the emitter of which goes to ground, so that when the transistor is
turned "on", pin 7 is effectively shorted to ground. Usually the timing capacitor is
connected between pin 7 and ground and is discharged when the transistor turns
"on". The conduction state of this transistor is identical in timing to that of the
output stage. It is "on" (low resistance to ground) when the output is low and "off"
(high resistance to ground) when the output is high. In both the monostable and
astable time modes, this transistor switch is used to clamp the appropriate nodes of
the timing network to ground. Saturation voltage is typically below 100mV (milli-
Volt) for currents of 5 mA or less, and off-state leakage is about 20nA (these
parameters are not specified by all manufacturers, however). Maximum collector
current is internally limited by design, thereby removing restrictions on capacitor
size due to peak pulse-current discharge.

Fig 4.10 555 timer tester

Pin 8 (V +): The V+ pin (also referred to as Vcc) is the positive supply
voltage terminal of the 555 timer IC. Supply-voltage operating range for the 555 is
+4.5 volts (minimum) to +16 volts (maximum), and it is specified for operation
between +5 volts and + 15 volts. The device will operate essentially the same over
this range of voltages without change in timing period. Actually, the most
significant operational difference is the output drive capability, which increases for
both current and voltage range as the supply voltage is increased. Sensitivity of
time interval to supply voltage change is low, typically 0.1% per volt.
Try the simple 555 testing-circuit of Fig. 5. to get you going, and test all
your 555 timer IC's. I build several for friends and family. I bring my own tester to
ham-fests and what not to instantly do a check and see if they are oscillating. Or
use as a trouble shooter in 555 based circuits. This tester will quickly tell you if the
timer is functional or not.

4.15 TRANSISTOR

A transistor is semi conductor device consisting of three regions separated

by two P-N junctions. The three regions are Base, Emitter & Collector.
The base may be of N- type or P- type. The emitter and collector have same
impurities but different from that of base. Thus if base is of N- type then emitter
and collector are of P- type then transistor is called P-N-P transistor and vice versa
transistor is called N-P-N transistor.
The base is made thin and number density of majority carriers is always less
than emitter and collector. The base provides junction for proper interaction
between emitter and collector.

4.16 SYMBOLS FOR TRANSISTORS

In schematic symbols, the emitter is always represented by an arrow

indicating the direction of conventional current in the device. In case of N-P-N
transistor arrow points away from base and in case of P-N-P transistor it points
towards base.

Fig 4.11 Structure and Symbol of P-N-P Transistor

4.17 BIASING OF TRANSISTOR

The two junctions can be biased in four different ways:

 Both junctions may be forward biased. It causes large current to flow across
junctions. Transistor is to be operated in ―SATURATION REGION‖.
 Both junctions may be reversed biased. It causes very small current to flow
across junctions. Transistor is to be operated in ―CUT OFF REGION‖.
 E-B junction is forward biased and C-B junction is reverse biased. The
transistor is said to be operated in ―ACTIVE REGION‖. Most of the
transistors work in this region.
 E-B junction is reversed biased and C-B junction is forward biased. The
transistor is said to be operated in ―INVERTED MODE‖.

(a) (b)
Fig 4.12
(a) P-N-P Transistor Biasing (b) N-P-N Transistor Biasing
(b)

4.18 CIRCUIT CONFIGURATIONS

There are three possible ways in which a transistor can be connected in the
circuit which are following:
 Common Base Configuration: Base is made common in this configuration.
 Common Emitter Configuration: Emitter is made common in this
configuration.
 Common Collector Configuration: Collector is made common in this
configuration.

4.19 DIODE

It is a P-type region and N-type region formed in the same crystal

structure, and hence a P-N junction is produced. Some of the conduction electrons
near the junction diffuse in to P-type semiconductor from the N-type
semiconductor across the junction combing with the holes.This region where
positive and negative charges develop is called depletion region.
If a P-region is made positive with respect to the N-region by an external
circuit then junction is forward biased and junction has a very low resistance to the
flow of current. Holes in the positive P-type material are attracted across the
junction to the negative side and the free electrons in the N-type material are like
wise attracted to the opposite side.

Fig 4.13 Volt-Ampere Characteristics of a P-N Diode

4.20 TEMPRATURE DEPENDENCE OF V-I CHARTERISTIC

The cut-in voltage decreases at the rate of 2.5 mV/°C. Also above 25°C, the

reverse saturation current I0 doubles for every 6°C (10°C) for Si (Ge) diodes.

However, the shape of overall characteristic does not alter with temperature.

4.21 RESISTANCE

Resistance is the electronic component used to control the current passing

through the circuit. They are calibrated in ohms. In the other words resistance are
circuit elements having the function introducing electrical resistance into the
circuit. There are three basic types:
1. Fixed Resistance
2. Rheostat
3. Potentiometer
A fixed Resistance is a two terminal resistance whose electrical
resistance is constant. A rheostat is a resistance that can be changed in
resistance value without opening the circuit to make adjustment.

Fig 4.14 Resistance

4.22 CAPACITOR

A capacitor is a device capable of storing an electric charge (static

electricity). It consists of two metal plates separated by dielectric material.

Capacitors are available in values ranging from less than one picofarad to

thousands of microfarad. While using a capacitor its ratings must be carefully

observed to make certain that the potential to be applied across the capacitor is not

greater than the rated value.

4.22.1 CERAMIC CAPACITOR

In this project, 0.01 microfarad capacitor is a ceramic capacitor. The basis

of the ceramic material is mainly barium titanate or a similar material, but other
ceramic substances including hydrous silicate of magnesia or talc are also used.
The electrodes are applied in the form of silver which is either spread or plated on
to the opposite faces of a thin tube, wafer or disc made from the ceramic material.
Connecting wires are then soldered to this deposit and the whole capacitor dipped
in for a suitable coating.

Fig 4.15 Tabular and Disc Type Ceramic Capacitors

4.22.2 ELECTROLYTIC CAPACITOR

In this project, 10f capacitor is an electrolytic capacitor. In this type of

capacitors, the dielectric consists of an extremely thin film of aluminum oxide
formed on one of its aluminum foil plates. Intimate contact with the other plate is
achieved by impregnating the paper between the foils with an electrolyte in the
form of viscous substance, such as ammonium borate. The sandwich is then rolled
into a cylindrical element and housed in either metallic cardboard, plastic or
ceramic protective tube.

Fig 4.16 Electrolytic and Tantalum Capacitor

4.23 INTEGRATED CIRCUIT:

Fig 4.17 Integrated circuit

 Integrated circuits were made possible by experimental discoveries which
showed that semiconductor devices could perform the functions of vacuum tubes,
and by mid-20th-century technology advancements in semiconductor device
fabrication. The integration of large numbers of tiny transistors into a small chip
was an enormous improvement over the manual assembly of circuits
using electronic components. The integrated circuits mass production capability,
reliability, and building-block approach to circuit design ensured the rapid
adoption of standardized ICs in place of designs using discrete transistors.

There are two main advantages of ICs over discrete circuits: cost and
performance. Cost is low because the chips, with all their components, are printed
as a unit by photolithography and not constructed as one transistor at a time.
Furthermore, much less material is used to construct a circuit as a packaged IC die
than as a discrete circuit.
 CHAPTER 5

FUTURE SCOPE

In a present scenario such kind of speed breaker are being used for a
light vehicles in various countries. Now in a future that technology can be used for
heavy vehicles, thus increasing input torque to various mechanism and ultimately
output of the generator or dynamo. To enhance the efficiency of that system,
engineers have to find out more compact, reliable and suitable mechanism to
produce electricity.
Future goal of that system to enhance the efficiency, so there should be rapid
rotation of the dynamo shaft; to do the same we can employ a flywheel to the
system in such a way that it would be increase the rotation per minute of dynamo
or a generator. Generally a flywheel used in machines serves as a reservoir which
stores energy during the period when supply energy more than the requirement and
releases it during the period when the requirement of energy more than the supply.
Flywheel energy storage (FES) works by accelerating a rotor (flywheel) to a very
high speed and maintaining the energy in the system as rotational energy.
Stepper motor can be replaced by the dynamo in single way traffic system
to produce electricity from speed breakers. Stepper motors operate differently from
normal DC motors, which rotate when voltage is applied to their terminals. Stepper
motors, on the other hand, effectively have multiple "toothed" electromagnets
arranged around a central gear-shaped piece of iron. The electromagnets are
energized by an external control circuit. So when the next electromagnet is turned
on and the first is turned off, the gear rotates slightly to align with the next one, and
from there the process is repeated.
 5.1 STEPPER MOTOR

Stepper motors are constant-power devices (power = angular velocity x torque).

As motor speed increases, torque decreases. The torque curve may be extended by
using current limiting drivers and increasing the driving voltage.
Steppers exhibit more vibration than other motor types, as the discrete step
tends to snap the rotor from one position to another. This vibration can become
very bad at some speeds and can cause the motor to lose torque. The effect can be
mitigated by accelerating quickly through the problem speed range, physically
damping the system, or using a micro-stepping driver.

5.2 OPEN LOOP VERSUS CLOSED LOOP COMMUTATION

Steppers are generally commutated open loop, i.e. the driver has no feedback on
where the rotor actually is. Stepper motor systems must thus generally be over
engineered, especially if the load inertia is high, or there is widely varying load, so
that there is no possibility that the motor will lose steps. This has often caused the
system designer to consider the trade-offs between a closely sized but expensive
servomechanism system and an oversized but relatively cheap stepper.
A new development in stepper control is to incorporate a rotor position
feedback, so that the commutation can be made optimal for torque generation
according to actual rotor position. This turns the stepper motor into a high pole
count brushless servo motor, with exceptional low speed torque and position
resolution.
 5.3 TYPES

There are three main types of stepper motors.

 Permanent Magnet Stepper
 Hybrid Synchronous Stepper
 Variable Reluctance Stepper

5.4 TWO PHASE STEPPER MOTOR

There are two basic winding arrangements for the electromagnetic coils in a
two phase stepper motor: bipolar and unipolar.

5.4.1 UNIPOLAR MOTORS

A unipolar stepper motor has logically two windings per phase, one for each
direction of current. Since in this arrangement a magnetic pole can be reversed
without switching the direction of current, the commutation circuit can be made
very simple (e.g. a single transistor) for each winding. Typically, given a phase,
one end of each winding is made common: giving three leads per phase and six
leads for a typical two phase motor. Often, these two phase commons are internally
joined, so the motor has only five leads.
 CHAPTER 6

CONCLUSION

It is a non conventional type of producing the energy. The existing source of

energy such as coal, oil etc may not be adequate to meet the ever increasing energy
demands. These conventional sources of energy are also depleting and may be
exhausted at the end of the century or beginning of the next century. This project is
a one step to path of that way. The overall goal was to design the speed breaker
System while keeping the engineering, producer and customer models in check.
The reason why this feature was used more than all of the other features are
because the other features would not have as much effect on the complete system.
By changing the size and desirable price, weight and capacity can be realized.
We used a survey to find out how the price, weight and capacity were
scaled. Much was learned on how to and not to conduct a survey. A preliminary
survey should have been conducted to determine a realistic value of variables. Also
many of choices were not close enough together to get a reasonable cut off value.
Therefore the data that was produced using conjoint analysis was most likely not as
accurate as it could have been.
Future work would consist of a redesign of this model to see exactly how
much data we may be missing with the assumption that we made with low price,
weight and capacity. Despite all the assumptions, we still have realized that this
product can be very marketable and that the demand is extremely large which
means this is a viable design that will yield a high return on an investment.
 REFERENCES

1. Sharma. P.C. Principle of renewable energy system (Public printing

service, New Delhi, 2003)
2. Sharma. P.C. Non-Conventional power plants (public printing service,
New Delhi, 2003)
3. Mukherjee.D Chakrabarti.S, Non-conventional Power Plants(Public
printing service, New Delhi, 2005)
4. Miller.R, Power System Operation, (McGraw- Hill, New York, 1970)

Websites:

www.classle.net/projects/node/255
www.technicaljournalsonline.com/jers/.../Sakun%20madam.pdf
www.theiejs.com
www.mechanical project.com
www.JAET.com
PHOTOGRAPHY