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1. Einstein College Of Engineering
sir C. V. Raman Nagar,Tirunelveli-627 012.
Department of Mechanical
Engineering
ME8682 Design And Fabrication Project

2. Design & Fabrication Of Rack & Pinion
Aided Power Generation System
Presented by,
M . Esakiyappan (950620114003)
S . Rajkumar (950620114009)
S . Ramkumar (950620114011)
Stanly Johnson (950620114312)
Guided by,
Mr. D. Jeyachandran M.E.,
Assistant Professor.

3. Abstract
In the present scanerio the fossil fuel sources are fast
depleting and their combustion products are causing global
environmental problems.
So, it is inevitable to deal with some alternative sources. So,
one such mode can be possible with the aid of rack & pinion
mechanism. And it is considered as a better source to meet with
small scale energy demands ,Thereby focused to reduce the
usage of conventional polluting energy sources & energy losses
from major sources during quite long power transmissions.

4. Introduction
With the era of modernity, it demands the necessities of energy in
wide manner depending upon diverse fields of utilization in varying
manner.
Careful management is therefore important. One such alternative
is possible with the aid of rack and pinion mechanism, in which
mechanical actioned energy is convert to electrical energy.
Also by the means it helps to meet the small scale essential
energy demands with minimized cause - effects of pollution, One
such example of its applicable strategy as speed breakers in roads.

5. Constructional Components
 frame
 Helical
springs
 Rack
 Pinion
 Bulb
 conducting
wires
 Dynamo
 Shafts

6. Working Principle
 When the pressing action takes place over the moving part of
the frame component, it triggers the action of rack having
teeth at one side, Thereby the rack moves vertically up and
down direction.
 Again in addition with the aid of certain transmission units in
the system like gears, chain sprockets etc, the linear vertical
motion of the rack is converted to rotary motion of the pinion
in which the required electrical power is generated as the
resultant output from the mechanical action.

7. Advantages
It reduces the energy losses from major power
generation sources during power transmission by
introducing alternative independent small scale power
generation units.
It plays a role in minimizing the emissions of
hydrocarbons by setting up individual alternative small
scale power generation units which is free from pollution
affects.
 It plays a vital role by initiating sustainable strategy of
development in which development takes place is not
found harmful for future generation.

8. Disadvantages
It cannot meet the energy demands of medium scale and
large scale load demands.
It is noisy in operation.
It is having high wear and tear ratings due to increased
friction generation ratio during movement of mechanical
parts in the system.

9. Future Scope
While considering its application as in the manner of speed
breaker, then it can be designed for heavy vehicles, thus
increasing input torque and ultimately output of generator.
More suitable and compact mechanisms to enhance
efficiency.
It may also be used for light vehicle also.

10. Purchased components pictorial views

11. Design Calculation
 Calculation of spring
Material of the spring is mild steel
Modulus of rigidity G = 80×103N/mm2
Applied Force P = 900N(Assumption by taking average value)
Shear Stress τ = 500N/mm2
Spring index C = 6
Deflection y = 50mm

12. Calculation of spring diameter:
Shear stress τ = KS*(8PC/πd2)
KS = (4C-1)/(4C-4)+(0.815/C)
= (4*6-1)/(4*6-4)+(0.185/6)
Service factor KS = 1.286
500 = 1.286*(8*600*5)/(π*d2)
Wire diameter d = 6mm
Spring index C = D/d
6 = D/6
Mean coil diameter D = 36mm
Internal diameter Di = D-d = 36-6
= 30mm
Outer diameter DO = D+d = 36+6
= 42mm

13. Number of spring coil:
ymax = (8PC3n)/(Gd)
50 = (8*900*63Cn)/(80C103*6)
Number of spring coil n = 16
For Square and Ground end condition:
n’= n+2 = 16+2
=18
Free length:
Lf = n’d+ymax+0.15ymax
Lf = (18*6)+50+(0.15*50)
Free length Lf = 165.5mm

14. Pitch of spring coil:
Free length/(n’-1)
That is 165.5/(18-1)
Pitch of the spring = 9.735mm
Stiffness of spring:
K = (G*d4)/(8*D3*n)
K = (80*103*64)/(8*303 *16)
Stiffness of the spring K = 30N/mm

15. Calculation of power:
Force F = 900N
Mass of vehicle M = 90Kg (Assumption by taking average
value)
Height of the speed breaker h = 15cm
= 0.15m
Workdone W = Force*Distance
The output Power for one pushing force = (900*0.15)/60
Power P = 2.25watts

16. Pictorial Views Of The Mini-Project
3D VIEW RIGHT HAND SIDE VIEW

17. FRONT VIEW LEFT HAND SIDE VIEW

18. Conclusion
Thus, the rack and pinion mechanism is therefore being
found to be a system bearing with enormous ranges of
future scope and positive outcomes in the field of meeting
small scale energy demands for essential livelihood needs
like generating electricity for ensuring the steady
functioning of road-warning signals and also it plays a vital
role in reducing global warming by reducing transmission
losses through its alternate level of independent action
under mechanical force.

19. Cost Estimation
Serial numbers Name of Part or
Operation
Quantity Price in Rupees
1 Drilling - 300
2 Cutting - 400
3 welding - 350
4 Surface Finishing - 200
5 Chain & Sprockets 1 Pair 250
6 Open - coiled
helical spring (wire
diameter ⌀5mm,
Compressive)
3 370
7 12V Dynamo 1 300
8 Rack &⌀50mm
Pinion
1 each 360
Total 2530

20. References
1. Khan BH. Non-conventional energy resources. 2nd ed.
New Delhi: Tata McGraw Hill;2012.
2. Abhishek Gupta, N. M. (2016). Electricity Generation
from Speed Breakers. International Journal of Electrical and
Electronics Research, 135 - 139
3. bhandariv.b.”design of machines design” – tatamcgraw
hill,2007
4. prabhut.j.fundanmentals of machines design,2009
5. t.nejatveziroygal, alternative energy sources-iii,
hemisphere publishing co.,
6. Ramesh. R, Uday Kumar, Anandakrishnan ”renewable
energy technologies”,narosa publishing house, madras.