This document describes the design and fabrication of a road power generator (RPG) by Zulfiqar Ali and their team. The RPG aims to capture wasted kinetic energy from vehicles to generate electricity. It works by using an activator plate that converts vehicle motion into rotational energy via a rack and pinion system. This energy is then amplified using pulleys and stored in a flywheel connected to a generator. The document outlines the working principle, methods used, contributions made in designing components like the activator plate, and calculations showing the RPG can generate around 1 kW of power per day. Challenges faced and advantages like being environmentally friendly and requiring no fuel are also discussed.

1. Design & Fabrication of
Road Power Generator
By
Zulfiqar Ali
With
Team
Supervised by
Mr. Abdul Samad Memon
Assistant Professor

2. Contents Of Presentation
Introduction
Aims, Objectives & Scope
Working Principle of RPG
Methods Used
Main Work
Our Contribution
Conclusion

3. Introduction- Problem statement
• Is anyone happy with current situation of
electricity in Pakistan???

4. Introduction- cont.
 Project background
• Road power generator was invented by Perry John Underwood Arundel in 2010 .
• The invention relates to a kinetic energy accumulator
 Road power generator
• Road power generator captures wasted energy of the
vehicles.
• A research found that 15,000 to 20,000 vehicles travels
along each main road every day. source NSW roads and
traffic authority Australia.
• This volume of vehicle equates to 30,000-40,000 tons of
wasted energy per road per day.
.

5. Aims of the Project
• For meeting up the regular demand of energy we want to design a system
which will produce electricity without destroying the nature.
• Generating power by sustainable mechanism which can be installed on the
smooth road.
• The implementation of road power generator units on highway and busy
traffic roads of the city.

6. Project Objectives
 The main objectives of road power generator are:
 To design and develop a mechanism which minimizes energy crises.
 To provide the free electricity to near grid stations, street lights, sign boards,
and traffic signals etc.
 To provide electricity to the rural areas too.
 To provide electric power to the users without any fuel cost.
 To design noise less mechanism.
 To make the generator economically.
 Have the less impact on the environment.

7. Scope of The Project
• RPG could be prom (path) for the vehicle manufacturers and the government
to actively persuade production of electric cars and motor bikes.

8. Working Principle – Block diagram of
project
Activator plate
Linear to rotary motion with rack and pinion
mechanism
This small speed converted
into large one by pulleys
Using flywheel for
uniform speed
Flywheel connected to
dc generator or dynamo
Dc controller for
regulating current
Inverter for converting 12v DC to 220v AC

9. Working principle- Mechanism in detail
Bearing
Shaft
Radial arm
Activator plate Spring
Figure a
Figure b
Figurer c

10. Working Principle
Working Principle Of Road power Generator
Rack and pinion , pulleys system

11. Methods Used
 The study of available relevant literature on the topic.
 Consultation with the teachers at the Mechanical Engineering Department.
 Fabrication of Experimental Model.
 Discussion among students.

12. Fabrication of Experimental
Model

13. Main Work
Overview of Literature
• Innowattech Piezoelectric Generators
• Electricity Generating by use of roller mechanism
• Electricity Generating by Ramp
Design of Road Power Generator

14. Overview Of literature
 Innowattech Piezoelectric Generators
Fig: Snapshots Representing The Pilot Stages

15. Overview Of literature- cont.
 Electricity generating by use of
roller mechanism.
 Electricity Generating by use of
Ramp.

16. Design Of Road Power Generator
The road power generator (RPG) is basically a renewable energy supply system.
The RPG consists of four main components, with each component performing a
unique task. The four major components of the system are:
Prime mover or activator plate
Rack and pinion, Pulleys and belt drive system
(Amplifier)
Flywheel system
Dynamo or permanent magnet dc generator

17. RPG- Activator plate
• The material of the activator plate should be
one that produce friction and must sustain high
temperature because if the friction is too high it
start burning.
• We have selected material (nylon plastic)
because it has light weight . And having high
strength .
• In the design of activator plate a gap is provided
so that it moves smoothly .
• Teeth are produced to prevent debris etc.

18. RPG- Components
• Aluminum material is used to fabricate metallic components.
Flywheel
rack
Pinion
V-Belt
Pulley
Output
terminal
wires
Casing
Shaft

19. Road Power Generator

20. Output power calculation
• Before calculating power first we have to calculate force. As we observe that the motion of activator plate is
first backward and the driving force is wheel force which is the function of vehicle net torque, engine speed,
wheel speed, radius of wheel, and efficiency of vehicle.
Therefore formula Fw = (M× Ne × ȵ) ÷(r ×Nw) (a)
Where M= net torque
Ne = engine speed
ȵ= engine efficiency
r = radius of wheel
Nw =wheel speed
• To find applied force of wheel we get data from” transitional controller design for adaptive cruise control
systems.
The simulated results are used as presented in table

21. Output power calculation-cont.
Time (sec) Velocity (Km/hr) Net torque (N-
m)
Engine speed
(rpm)
Wheel speed
(rpm)
5 72 200 3100 636.9
6 75.6 199 3200 668.7
7 79.2 202 3300 700.6
8 82.8 201 3500 732.5
9 86.8 198 3650 761.33
10 90 199 3780 796.17
11 95.6 195 3840 828.025
12 97.2 195 3920 859.87
13 100.8 191 3995 891.72
14 104.4 186 4130 923.56
15 108 182 4237 955.41
Wheel Force data table 1

22. Output power calculation-cont.
• With the help of table we can calculate force which is driving force of the plate, we
assumed that efficiency of vehicle is 0.38 and wheel radius is 0.3 m.
• Therefore if we assume that vehicle moves at speed of 90km/hr then by using table 1
and equation (a) we can calculate that driving force is equals to
F=1196.74 N.
• We assume that the distance of the plate = 5cm
Therefore Fw = 1196.74 N
Work done = force × distance
Work done = 1196.74× 0.05 = 59.837 joules
Output power = Work done / sec = 59.837 /60 = 0.99728 watts

23. Output Power calculation-cont.
Power developed for 1 vehicle passing over the generator is .99728
watts; due to flywheel it delivers power for one minute
continuously. So the Power developed for:
1 hr = 59.83 Watts
24hr = 1.43 KW

24. Graphs

25. Graph

26. Advantages and limitations
 The RPG units have minimum visual impact
on their surrounding environment.
 Road power generator emits no noise, the unit
has relatively low set up and trailing costs.
 Highly efficient in more volume of vehicle
places.
 Depending upon the power generator and
number of them, power output is very high.
 It has simple construction.
 Less area is required.
 Easy maintenance.
 No consumption of any fuel.
 Power will be generated throughout the year.
Advantages
 There would be no generation of
power when there is no vehicle
passing over the system.
 There would be small jerk feel by
the passengers.
 It can sustain limited load of
vehicles.
 Power only generated if vehicles
flow is constant and about 10-20
vehicles are required for initial
movement.
Limitations

27. Our Contribution- Challenges we
faced!!
• Designing of major components of project.
• Fabrication of the mechanical parts.
• Selection of material for making project feasible.
• Survey of major road’s traffic for measuring the volume of vehicles.
• Project economics
• All manufacturing processes like, casting of pulleys and flywheel,
machining of activator plate, shafts, rack and pinion and finishing
assembling of these parts.
• Selection of bearing. Belts, springs and shafts etc.
• Collect data of different vehicles includes weights, speeds.
• Output power calculation ,and dynamics of the project.

28. Conclusion
o Road Power Generation is a new type of unconventional source of
energy. This uses wasted energy of moving vehicles.
o In coming days, it will prove a great boon to the world, since it will save
a lot of electricity of power plants that gets wasted in illuminating the
street lights, and other road usage.

30. Thank you.