A PROJECT REPORT ON

DESIGN AND FABRICATION OF GENERATION

OF ELECTRICITY THROUGH SPEED BREAKER
MECHANISM
Submitted in partial fulfillment of the requirements for the award of degree of

BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING

DR. SIVANTHI ADITANAR COLLEGE OF ENGINEERING,

TIRUNCHENDUR

ANNA UNIVERSITY::CHENNAI – 600 025

APRIL-2021

SUBMITTED BY

AABAL SYLO M (950518114001)

AJAY CHOCKALINGAM (950518114002)

ARAVINTHAN (950518114005)

ARUL RAJ A (950518114006)

Under the guidance of

Dr. A. Maniram Kumar,ME,PhD,MBA
M.Phil,MBA[Edn.mgmt],MISTE,MIE

HEAD OF THE DEPARTMENT

Dept. of Mechanical Engineering, SACOE
 ANNA UNIVERSITY : CHENNAI 600 025
DEPARTMENT OF MECHANICAL ENGINEERING

Certificate
Certified that the project work entitled
“DESIGN AND FABRICATION OF GENERATION OF ELECTRICITY
THROUGH SPEED BREAKER MECHANISM ”

Is the bonafide work of “M. AABAL SYLO, AJAY CHOCKALINGAM,

ARAVINTHAN, A. ARUL RAJ ” who carried out the project work under my

supervision.

SIGNATURE SIGNATURE
Dr. A. MANIRAM KUMAR,ME,PhD,MBA Dr. M. CHITHAMBARA THANU, BE,ME,Ph.D,MISTE
M.Phil,MBA[Edn.mgmt],MISTE,MIE
HEAD OF THE DEPARTMENT, HEAD OF THE DEPARTMENT,
Mechanical Engineering, Mechanical Engineering,
Dr. Sivanthi Aditanar College of Engineering, Dr. Sivanthi Aditanar College of Engineering,

Submitted for the project viva-voce examination held at Sivanthi Aditanar college of
Engineering on ________________

------------------------------- -------------------------
Internal Examiner External Examiner
 ACKNOWLEDGEMENT

We would like to express our sincere thanks and gratitude to

Dr. G. Wiselin Jiji BE.,ME.,Ph.D.,MISTE Principal, Dr. Sivanthi Aditanar College
of Engineering, for allowing us to undertake the design and fabrication project works
successfully.

We people very much thankful to our guide Dr. A. MANIRAM KUMAR

HOD of, Department of Mechanical Engineering, Dr. A. Maniram
Kumar .,ME.,PhD.,MBA.,M.Phil.,MBA[Edn.mgmt].,MISTE.,MIE for his thought
providing ideas throughout the entire span of our Project Work.
We wish to thank Dr. M. CHITHAMBARA THANU, BE.,ME.,Ph.D.,MISTE Assistant
professor of our Department and staff in charge of this design and fabrication project
for his inspiring motivation and we also wish to thank
Dr. A. Maniram Kumar, ME.,PhD.,MBA.,M.Phil.,MBA[Edn.mgmt].,MISTE.,MIE Head of the
Department for the success of this mini project work.
At last I would like to thank all our department staff, skilled assistants and
others for their valuable suggestion for the completion of this project.
 ABSTRACT  
 
           Electricity is generatedby replacing the usual speedbreakers with some simple mechanism. As vehicles
pass over the speedbreakers, rack and pinion mechanism works and with the help of high tension springs in
turn generate electricity.
 
           
          In the present situation power becomes basic need for human life. Energy is responsible for major
developments of any country’s economy. Conventional energy sources generate most of the energy of today’s
world. But the population is increasing day by day and the conventional energy sources are diminishing.
Moreover, these conventional energy sources are polluting and responsible for global warming. So, non-
conventional sources are needed to be developed for power generation which are clean, environment friendly
and sustainable.
 
            
          In this research we propose a renewable non-conventional energy source based on speed breaker
mechanism. Our project is to enlighten the streets utilizing the jerking pressure which is wasted during the
vehicles passes over speed breaker in roadside. We can tap the energy generated by moving vehicles and
produce power by using the speed breaker as power generating unit.
 
          
           The kinetic energy of the moving vehicles can be converted into mechanical energy through rack and
pinion mechanism and this mechanical energy will be converted to electrical energy using generator which
will be used for lighting the street lights. Therefore, by using this mechanism we can save lot of energy which
can fulfill our future demands.
 
            It is very significant to design pollution free energy generation system. Speed breaker Power
Generator (SBPG) is the • most emerging technique which produces electrical power with minimum input. An
experimental study to generate the • electricity by SBPG is described in this paper.
 
             In this system, a rack and pinions mechanism is used for the production • of electricity. When a car
reaches on the speed breaker, the rack moves downward to generate linear to rotary motion • using pinions.
The rotary motion is transferred to DC generator which generates DC power which is stored in batteries •
same as in solar technology.
 
              The generated power can be used for the domestic purpose or commercially, which are •
present near the speed breaker. This examined that SBPG is generating 273.24W on single push
under the application • of 400kg. In an hour, passing 100 cars of 400kg can generate 54.59 kWh.
This mechanism utilizes both downward as • well as the upward motion of the rack.
 CONTENTS
Acknowledge 3
Abstract 4
Contents 5

Particulars

CHAPTER 1: INTRODUCTION

1.1 INTRODUCTION ……………………………………………………… 9

1.2 SCOPE OF THE PROJECT ……………………………………………………… 9

CHAPTER 2: DEMONSTRATION OF THE PROJECT

2.1 WORKING PRINCIPLE ………………………………………………………… 11

2.2 BLOCK DIAGRAM ………………………………………………………… 11

CHAPTER 3: MODELLING,SIMULATION AND RESULTS

3.1 FABRICATION DETAILS ……………………………………………………. 13
3.2 FABRICATION MODEL SHOWING IN INNER PARTS ……………………. 13
3.3 MATERIALS USED ……………………………………………………….. 13
3.4 ADVANTAGES ………………………………………………………….. 14
3.5 DISADVANTAGES …………………………………………………………... 14

CHAPTER 4: ACCESSORIES REQUIRED

4.1 RACK AND PINION ………………………………………………………….. 16
4.2 SPROCKET ……………………………………………………………. 16
CHAPTER 5: CHAIN DRIVES
5.1 CHAIN DRIVES …………………………………………………………………. 19
5.2 CHAIN DRIVE DESIGN …………………………………………………………. 19
CHAPTER 6: WHEELS AND SPRINGS
6.1 FREEWHEEL ……………………………………………………………….. 21
6.2 FLYWHEEL ………………………………………………………………… 21
6.3 SPRINGS …………………………………………………………………. 22

CHAPTER 7:CALCULATIONS
7.1 OUTPUTPOWER CALCULATIONS ……………………………………….23
 CHAPTER 1

INTRODUCTION
1.1 INTRODUCTION:

The need of power is gradually increasing nowadays due to

technology • Growth many industries needs the thermal power is the
largest source of power in India about 71% of electricity is consumed in
India is generated from thermal power plant one more way to generate
power is by cogeneration processes here we getting power from the
speed breaker due to to the reciprocating motion.

1.2 SCOPE OF THE PROJECT:

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.
 CHAPTER 2

DEMONSTRATION OF THE PROJECT

 CHAPTER 2

DEMONSTRATION OF THE PROJECT

2.1.1 WORKING PRINCIPLE

A large amount of energy is wasted by the vehicles on the speed breakers through
friction, every time it passes over it. Energy can be produced by using the vehicle weight and speed. So
here we propose a smart speed breaker that generates power. The reciprocating motion of the speed
breaker is converted into rotary motion using the rack and pinion arrangement. We design a smart speed
breaker that can pass vehicles coming from both sides and yet generate energy from it. The system makes
use of mechanical assembly with metal sheets with linkages that press down with spring arrangement.
The system makes use of the speed breaker press and then uses a rack and pinion arrangement to press
down and run generator motor thus generating energy. The spring mechanism is the used to drive the
speed breaker back into original position. It converts rotary motion into linear motion, but sometimes we
use them to change linear motion into rotary motion. This mechanism is very economical and easy to
install. By doing proper arrangements we may generate high power electricity from road traffic

2.1.2 BLOCK DIAGRAM

CHAPTER 3
MODELLING , SIMULATION AND RESULTS
 CHAPTER 3
MODELLING , SIMULATION AND RESULTS
3.1 FABRICATION DETAILS

Metal fabrication is the process of building machines and structures from raw

metal materials. The process includes cutting, burning, welding, machining, forming,
and assembly to create the final product. Metal fabrication projects include everything
from hand railings to heavy equipment and machinery.

3.2FABRICATION MODEL SHOWING INNER PARTS

Wire are connected to the terminals of the DC generator and its other end
are connected to a Lead – Acid battery. Another wire are taken from these point on
the battery and its other ends are connected to thepositive and negative terminal of
an inverter

3.3 MATERIAL USED

The system makes use of mechanical assembly with metal

sheets with linkages that press down with spring arrangement. The system
makes use of the speed breaker press and then uses a rack and pinion arrangement
to press down and run generator motor thus generating energy.

3.4 SPECIFICATIONS

Generator – 12v DC generator

Battery - Lead-Acid Battery

Inverter - 250W
3.5ADVANTAGES
1. Require simple construction methods

2. Free from all types of pollutions

3. It is economical and easy to install

4. Maintenance cost is low.

5. No consumption of fossil fuel which is nonrenewable.

6. No manual work necessary during generation.

3.6 DISADVANTAGES
1. Shafts are required to be mounted properly otherwise it creates balancing problem.

2. Mechanical vibration causes problem.

3. It will produce considerable amount of output mainly with heavy vehicles hence is not
much suitable for light vehicles.

4. May get damaged in rainy season if not shielded properly.

5. Maintenance on regular basis is needed to check fault in either mechanical system or

piezoelectric crystal.
 CHAPTER 4

RACK ,PINION AND SPROCKET

 CHAPTER 4
RACK AND PINION , SPROCKET

4.1 RACK AND PINION

Rack and pinion gears normally change rotary motion into linear motion, but
sometimes we use them to change linear motion into rotary motion.
They transform a rotary movement (that of the pinion) into a linear movement
(that of the rack) or vice versa.

We use them for sliding doors moved by an electric motor.The rack is attached
to the door and the pinion is attached to the motor. The motor moves the pinion which
moves the rack and the door moves.

4.1 SPROCKET

A sprocket, sprocket-wheel or chainwheel 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 radial projections engage a chain
passing over it.
 CHAPTER 5

CHAIN DRIVES
CHAPTER 5
CHAIN DRIVES

5.1 CHAIN DRIVES

Chain drive is a way of transmitting mechanical power from one place to another. It is
often used to convey power to the wheels of a vehicle, particularly bicycles and
motorcycles. It is also used in a wide variety of machines besides Vehicles

5.2 CHAIN DRIVES DESIGN:

Chain drives are flexible and made of number of links and its a

intermediate between belts and gears drives. Chains can only be used to transmit
power between parallel shafts. Unlike belt drives, chain drives uses special toothed
wheels called sprockets.
 CHAPTER 6
WHEEL AND SPRINGS
CHAPTER 6
WHEEL AND SPRINGS
6.1 FREE WHEEL
In mechanical or automotive engineering, a freewheel or
overrunning clutch is a device in a transmission that disengages the
driveshaft from the driven shaft when the driven shaft rotates faster
than the driveshaft. An overdrive is sometimes mistakenly called a
freewheel, but is otherwise unrelated.

6.2 FLY WHEEL

A flywheel is a mechanical device specifically designed to

use the conservation of angular momentum so as to efficiently store rotational
energy; a form of kinetic energy proportional to the product of its
moment of inertia and square of its rotational
6.3 SPRINGS

A sprin
g is an elastic object that
stores mechanical energy. 
Springs are typically made
of spring steel. ... The rate
or spring constant of
a spring is the change in
the force it exerts, divided
by the change in deflection
of the spring. That is, it is
the gradient of the force
versus deflection curve.
 CHAPTER 7
CALCULATIONS
 CHAPTER
7
CALCULATION

7.1 OUTPUT POWER CALCULATION

Experimental study and results

Consider 100 cars of mass 400kg pass over a speed breaker in an hour. The height of rack
is 14cm, the diameter of the final pulley is 18mm and having revolution speed (N) is
equal to 37 RPM. Down word motion of speed breaker is due to the weight of moving the
vehicle and upward motion of speed breaker is take place due to the utilization of energy
from springs. Each car pushes speed breaker two times.
Force = F = mg (1)
F = 400 x 9.8 = 3920N
r = 9mm
T = r x F (Nm) (2)
T = 9x 10-3 x 3920

T = 35.28 (Nm)
P = T.ω(3)
P = 35.28 x 2πN/60
P = 35.28 x (2 x 3.14 x 37)/60
P = 136.62 W
Total generated in forward and reversed stroke.
P = 2 x 136.62 W
P = 273.24 W
Revolution in one minute = 200/60 = 3.33rev/min
Power generated per minute = 273.24 ×3.33
= 909.89 W (minute)
Power generated in one Hour = 909.89 x 60
= 54.59 KW (hour).
Different masses are applied on the speed-breaker and the measured the electrical power.