This Slide deals with generating power using a speed breaker.This technology can be implemented on highways and cities and mostly at toll booths.

1. MAHARASHTRA ACADEMY OF
NAVAL EDUCATION &
TRAINING,(PUNE)
BACHELOR OF TECHNOLOGY IN MARINE ENGINEERING
TECHNICAL PAPER PRESENTATION
YASHWANTRAO CHAVAN MAHARASHTRA OPEN UNIVERSITY
(2015-2016)
GUIDED BY : Prof.

3. GROUP
MEMBERS

4. GROUP MEMBERS
Submitted By:
1. Raza Ishtiaq. (Group Leader) (11106)
2. Nikhil Nishant. (11089)
3. Nikhil Mayank. (11088)
4. Piyush Kumar. (11095)
5. Pradeep Kumar. (11096)
6. Pratit Rajak. (11099)
7. Rishav Kumar. (11107)
8. Rohit Kumar. (11109)
9. Devendra Bansal. (11023)
10.Devendra Chaurasia. (11027)
________________ _________________ ________________
Prof. V.G.Mehendale Prof . Q. Tayabji Prof . S. Devgaonkar
( Project Guide ) ( Head Of Ship - In- Campus ) ( Principal )

5. CERTIFICATE:
This is to certify that the project entitled: “ELECTRICITY GENERATION FROM SPEED BREAKER”
Sr. No. Name of Cadet PRN No. Sr. No. Name of Cadet PRN No.
01 Raza Ishtiaq VV2300047 06 Pratit Rajak VV2300127
02 Nikhil Nishant VV2300113 07 Rishav Kumar VV2300080
03 Nikhil Mayank VV2300101 08 Rohit Kumar VV2300081
04 Piyush Kumar VV2300077 09 Devendra Bansal VV2300013
05 Pradeep Kumar VV2300078 10 Devendra Chaurasia VV2300018
In partial fulfillment for the requirements of
Bachelor of Technology ( Marine Engineering )
____________ ____________
Prof. V.G.Mehendale (Internal Examiner (External Examiner)

6. ACKNOWLEDGEMENT
This project work is made explaining about the installation of a Electricity Generating
Speed Breaker in our campus. Many people have made their best contribution to make
this project a success.
We wish to thank a number of people who have taken efforts and helped us in the best
way possible in our project and made it successful.
We would like to thank professors for guiding us through the project. Our sincere thanks
goes to Professor Qaiser Tayabji (head of ship in campus), Prof. R.K. Vaidya and Prof. S. V.
Joshi who have helped us immensely throughout our project.
Our project is a success because of the guidance and a pathway shown by our project
guide Professor V.G. Mehendale, so a quote of thank will be incomplete without thanking
him.
And finally we would like to thank our ship in campus college staff and personnel as well
as our workshop staff, for their grateful help and support in helping to realize this project.

7. TABLE OF CONTENTS
Sr.No. Topic Page No.
01 INTRODUCTION 08-12
02 ESTIMATED OBJECTIVE 13-14
03 MATERIALS REQUIRED 15-16
04 SYSTEM OVERVIEW & DESIGN 17-22
05 MODULE DESIGN 23-51
06 TESTING & TROUBLESHOOTING 52-53
07 CONCLUSION 54-55
08 BOOKS REFERRED 56

8. INTRODUCTION

9. INTRODUCTION
 The current situation of power shortage in the world
is nothing but grim.
 So, this is our small step to try to improve this situation
by our project.
 In India alone ,there are more than 60 million
vehicles on the roads everyday.
 The project makes use of pressure energy of the
vehicle passing over the speed breaker and
converts it into electrical energy with the help of
various gears and spring systems .

10.  Making use of the mechanism we can install it on
highways primarily at Toll-Gates and other various
places.
 Other places where the project can be used
includes parking lots, malls etc. Alternately this can
also be used as a security system for vehicle parking
, where the alarm can be connected to the output
so that when the vehicle passes over the speed
breaker , an alarm circuit can be triggered.

11. • Onboard Application: It can be fitted onto the
entry gate of a Roll-On & Roll-Off ship where on an
average, around 2000 vehicles enter & exit & each
vehicle having at least two wheels, therefore on an
average the speed breaker can be pressed around
4000 times at a given loading/unloading time. The
energy so produced, can be stored in a large
capacity battery and can be used to operate the
Gate of the Ro-Ro ship, or some local lighting
provision can be made available.

12. OBJECTIVES
• To develop clean & green source of electricity.
• To tap the potentially useful potential energy from
vehicles plying on the roads.
• To make an alternative for developing a unique & cheap
method of producing energy.

13. ESTIMATED
OBJECTIVES

14. Estimated Objective
On completion of the project
• We will be able to generate enough power that can light
up a L.E.D. lamp when a single vehicle passes over the
speed breaker.
• This energy may alternately be tapped and stored in a
battery or a capacitor-bank , which can then be used
whenever required.
• Specific options on power usage include using in Vehicle-
counters entering the campus , In Rooms illuminated by
L.E.D.s or in RFID Sensors on vehicles.

15. MATERIALS
REQUIRED

16. Materials Required
Serial No. Part Type Quantity Estimated
Cost
1 Springs Helical 02 -
2 Gears Rack &
Pinion
01+01 580+1040
3 Gears 03 1470+386
4 Bearings Ball 08 567
5 Motor Synchronous 01 3937.5
6 Nut 16X75 04 105
7 Nut Bolts &
Washer
5X16 16 192
8 Paint & Brush - 02+01 230
TOTAL 8507.5/- INR

17. Syst emOVERVIEW
& dESIGN

18. • The system makes use of the general speed breaker
arrangement with the modification that the speed
breaker itself travels in a vertical axis & having a Spring
under it to push it back to its original position.

19. TOP PLATE
SPRING
BEARING CARRIER
SYNCHRONOUS MOTOR
BEARING GUIDE
RACK
PLATE
BOTTOM PLATE
• When the TOP PLATE goes down due to the weight of
the vehicle,the RACK that is welded to the TOP PLATE
travels in a vertical direction downwards and rotates
the gears that are meshed with it & hence giving the
rotation to the gear mounted on the motor,thereby
rotating the rotor of the motor & generating electric
power.

20. TOP VIEW
GEAR 1
PLATEMOTOR
RACK GUIDE
PLATE FOR
SUPPORTING MOTOR

21. SIDE VIEW
INCLINED RAMP
HORIZONTAL RAMP
SPEED BREAKER

22. MODULEdESIGN

25. We have used two number of plates for forming the top and base of our speed breaker
BOTTOM PLATE
TOP PLATE
The plates are made up of MILD STEEL. The dimensions of which are given as follows:
TOP PLATE : 80*46 cms THICKNESS : 1cm
BOTTOM PLATE : 100*50 cms THICKNESS : 1cm

26. After we furnished the whole setup, we decided that the travel of the top plate would be 8 cm.
Due to this we stumbled upon the problem of bumping of the vehicle onto the ramp when it
passes over the speed breaker, due to which, the vehicle may disbalance. The representation
of which is as given below.
The vehicle may bump
dangerously at this point

27. Therefore we devised a solution for it. With the help of flexible plate of MILD STEEL, we can
successfully negate the above problem of bumping. The plate will be placed under the exposed
surface of speed breaker i.e. under the rubber mat that we are using in our case. The flexible plate
will extend onto both the ramps where it will be bolted for fixing them and also there will be slots cut
around the hole for the bolt so that there will be a slight movement for the plate when it deforms
under the load of the vehicle.

29. We have used two number of Helical Springs which are placed in between the top and base
plate. These spring will actually bear the load of the vehicle and will compress when the
vehicle will pass over the top plate & then return to its original position when the vehicle passes.
The Dimensions of the spring are as follows:
• MATERIAL OF SPRING: Spring Steel
• FREE LENGTH: 37.5cm
• OUTER DIAMETER: 10cm
• THICKNESS OF EACH COIL (d): 10mm
• NUMBER OF ACTIVE COILS: 6

31. RACK CALCULATIONS:
Assumptions:
Module = 2mm
Number of Teeth = Compression length / (module*3.14)
= 80/(2*3.14) =12.74 or 13
Length of rack = Number of teeth * module * 3.14 = (13*2*3.14) = 82mm =82+20+20=122mm
Width of rack = 20 mm
GEAR CALCULATIONS: (Trial & Error Method)
For 1st Pinion
m ≥ 1.26 ×
3
(𝑇/y×(σ×ψ×z))
Where:
m= Module
T= Torque on tooth × (F.O.S. =1.3)
Y=Form Factor=0.36
σ= Design Bending Stress=120 N/𝑚𝑚2
Ψ=Face Width / Module =10
Z=Number of teeth=16 (Assumed)

32. So, torque on tooth= 120 × 9.81 × 16 Nmm
=18835.2 Nmm
It is assumed that the load is of 120 Kg on the rack.
Now, m= 1.26 ×3
18835.2/(0.36×120×10×16) =1.92
Hence it is safe to operate at m < 2.
So,Number of teeth= 16
Module (m)=2
Face Width(ψ)=20mm
P.C.D. =32mm
Now,
Formula Used= Speed of driver (𝑁1) = Number of teeth on driven(𝑇2)
Speed of driven (𝑁2) Number of teeth on driver (𝑇1)

33. 1st Reduction of Speed:
So,RPM= 1164.6 × 16 = 310.56 R.P.M.
60 (Assumed)
Then, 1st gear Specifications:
Number of teeth= 60 (Assumed)
Module (m)=2
Face Width(ψ)=20mm
P.C.D.=120mm
Also , m= 1.26 ×3
18835.2×1.3/(0.36×120×10×60) =1.24
It is safe to operate as m<2
For 2nd Pinion
m= 1.26 ×3
18835.2×1.3/(0.36×120×10×12) =1.68
It is safe to operate as m<2
So, Number of teeth=12 (Assumed)

34. Module (m)=2
Face Width(ψ)=20mm
P.C.D.=120mm
For 2nd Reduction of speed
So,RPM= 310.56 × 12 = 53.27 R.P.M.
70(Assumed)
Then, 2nd gear Specifications:
Number of teeth= 70 (Assumed)
Module (m)=2
Face Width(ψ)=20mm
P.C.D.=140mm
Also , m= 1.26 ×3
18835.2×1.3/(0.36×120×10×70) =1.17
It is safe to operate as m<2.

35. Spring Guides:
Material Used: Mild Steel (M.S.)
Top Spring Guide :
• Length = 25cm
• Outer Diameter = 60mm
• Thickness = 0.5cm
Bottom Spring Guide :
• Length = 29.5cm
• Outer Diameter =68mm TOP SPRING GUIDE BOTTOM SPRING GUIDE
• Thickness =0.5cm

37. We have designed 3 number of shafts for mounting gears in our project. These shafts were then
suitably machined for making keyways so that the gear can be locked onto the shaft with proper
keys that fit in the keyway of the shaft & gear. The dimensions of the shaft are given below:
Shaft 1 :
Length : 50mm
Diameter : 12mm
Shaft 2 :
Composite Shaft
Section 1: Length : 50mm
Diameter : 16mm
Section 2: Length : 50mm
Diameter : 12mm
Shaft 3 :
Length : 50mm
Diameter : 16mm
SCALE 1:1
SCALE 1:1
SCALE 1:1

39. Deep groove (Conrad) bearing
 Primarily designed to support radial loads, the
thrust capacity is about 70% of radial load
capacity.
 Load capacity is limited by the number of
balls.
Ball Bearings

40. Bearings
• Rolling Contact Bearings – load is transferred through
rolling elements such as balls, straight and tapered
cylinders and spherical rollers.
• Journal (sleeve) Bearings – load is transferred through
a thin film of lubricant (oil).

41. Bearings
Rolling Contact Bearings-Load is transferred
through elements in rolling contact rather
than sliding contact.

42. Design Considerations
 Bearing life and reliability
 Bearing speed (rpm)
 Space limitation
 Accuracy
• Bearing load – radial, thrust (axial) or both.
Radial loadRadial load
Thrust load
Bearings are selected from catalogs, before
referring to catalogs you should know the
following:

43. Single -Row Deep Groove Ball
Bearing
Typical ball bearing. Handles light
axial loads as well as radial loads .

44. We have used 4 in number of bearings in our project. The bearings are
fixed in a square pipe. Each bearing is bolted onto a single pipe, the
dimensions of which are as given below:
• Length of each pipe = 19.5cm
• Width = 3.5cm (of each side of square)
The Dimensions of the Bearings are as follows:
• Outer Diameter = 40cm
• Bore = 16cm
Also we have used guides for bearings,the dimensions of
which are as follows:
• Length = 26cm
• Width = 5cm
• Inner Width = 4.5cm
• Thickness = 0.025cm
INVERTED VIEW OF SQUARE
PIPE WITH BEARING BOLTED

46. We have used a Synchronous Motor to generate electric power. The
Specifications of which are as follows:
SINGLE-PHASE SYNCHRONOUS MOTOR (REVERSIBLE)
R.P.M. = 60
Voltage = 240 Volts
Frequency = 50 Hz
Torque = 26 Kgcm

51. TESTING
&
TROUBLESHOOTING

52. PROBLEMS AND SOLUTIONS:
• SELECTING SUITABLE MOTOR
• SELECTION OF SPRINGS
• ACHIEVING PROPER BALANCE OF SPRING AND TORQUE
• PRESS FITTING OF BEARINGS INTO THE PLATE
PROBLEM 1: LOAD TESTING OF SPRINGS-one of the basic principle of the
spring is to withstand a force while having the ability to compress or
extend and then to return to its original position.
SOLUTION: We carried out the load testing of different springs ,to see
whether the springs can withstand the load of the vehicle.
It was carried out in a very simple manner(trial and error) -the springs
were aligned between two plates , different weights were applied on
the springs and the compression were noted down the weights varied
from 60 kgs to 180 kgs and was tabulated and compared with our
decided travel, after testing 2 springs we came up with the springs that
was suitable for the load variation between 60 -200 kgs.

53. PROBLEM 2: When we assembled the gears and coupled the motor to the
gears, we noticed that the torque produced was not enough to drive the
motor to the extent at which it generated electricity.
SOLUTION: When we removed all but one gear and meshed the gear that
drove the motor, with the rack we could get the desired output instantly.
PROBLEM 3: When we were press fitting the bearing onto the plate, due to
mechanical error, the diameter of the hole in the plate was made more than
that of the outer diameter of the bearing, making it loose.
SOULTION: We welded along the internal diameter of the hole in the plate &
the again machined the hole carefully on the lathe machine.

54. CONCLUSION

55. 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.
This project is one step to path of exploring the possibilities of
energy from several non-conventional energy sources, this is a
type of vibration harvesting .This uses waste energy of vehicles
and converts kinetic energy to electrical energy.
future work can consist of re-designing of this model to see
exactly how much data we may be missing with the project
we came up with low price, weight and capacity.

57. Thank
you