Power generation using speed breakers

CHAPTER - 1
INTRODUCTION
In the present scenario power becomes the major need for human life .The
availability and its per capita consumptions is regarded as the index of national
standard of living in the present day civilization. Energy is an important input
in all the sectors of any countries economy. Energy crisis is due to two reasons,
firstly the population of the world has been increased rapidly and secondly
standard of living of human beings has increased.
India is the country, which majorly suffers with lack of sufficient power
generation. The capital energy consumption of U.S.A. is about 8000 K.W.H.,
where as per INDIA is only 150 K.W.H. U.S.A. with 7% of world population
consumes 32% of total power generation where as INDIA as developing
country with 20% of world population consumes only 1% of total energy
consumed in the world.The availability of regular conventional fossil fuels will
be the main sources for power generation, but there is a fear that they will get
exhausted eventually by the next few decades. Therefore, we

have to

investigate some approximate, alternative, new sources for the power

generation, which is not depleted by the very few years.
Another major problem, which is becoming the exiting topic for today is the
pollution. It suffers all the living organisms of all kinds as on the land, in aqua
and in air. Power stations and automobiles are the major pollution producing
places. Therefore, we have to investigate other types of renewable sources,
which produce electricity without using any commercial fossil fuels, which is
not producing any harmful products.
Fuel deposit will deplete soon by the end of 2020 .Fuel scarcity will be
maximum. Country like India may not have the chance to use petroleum
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Power generation using speed breakers

products. Keeping this dangerous situation in mind we tried to make use of

non-pollutant natural resource of petrol.
There are already existing such systems using renewable energy such as solar,
wind), OTEC (ocean thermal energy conversions) etcfor power generation.
The latest technology which is used to generate the power by such renewable
energy is the POWER HUMP.
An energy crisis is great bottleneck (or price rise) in the supply of energy
resources to an economy. It usually refers to the shortage of oil and additionally
to electricity or other natural resources. An energy crisis may be referred to as
an oil crisis, petroleum crisis, energy shortage, electricity shortage electricity
crisis. A crisis can develop due to industrial actions like union organized strikes
and government embargoes. The cause may be ageing over-consumption,
infrastructure and sometimes bottlenecks at oil refineries and port facilities
restrict fuel supply.
This is our step to improve the situation of electricity with an innovative and
useful concept i.e. Generating Electricity from a Speed breaker. Electricity is
the form of energy. It is the flow of electrical Power. Electricity is a basic part
of nature and it is one of our most widely used forms of energy. We get
electricity, which is a secondary energy source, from the conversion of other
sources of energy, like coal, natural gas, oil, nuclear power and other natural
sources, which are called primary sources.
Many cities and towns were built alongside waterfalls that turned water wheels
to perform work. Before electricity generation began slightly over 100 years
ago, houses were lit with kerosene lamps, food was cooled in iceboxes, and
rooms were warmed by wood-burning or coal-burning stoves. Direct current
(DC) electricity had been used in arc lights for outdoor lighting. In the late1800s, Nikola Tesla pioneered the generation, transmission, and use of
alternating current (AC) electricity, which can be transmitted over much greater
distances than direct current. Tesla's inventions used electricity to bring indoor
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Power generation using speed breakers

lighting to our homes and to power industrial machines. How is electricity

generated? Electricity generation was first developed in the 1800's using
Faradays dynamo generator. Almost 200 years later we are still using the same
basic principles to generate electricity, only on a much larger scale.
This project is about GENERATION OF ELECTRICITY BY USING SPEED
BREAKERS. This is one of the best suitable solutions to the electricity crisis.
This project will work on the principle of MECHANICAL ENERGY TO
ELECTRICAL ENERGY CONVERSION.
In this project a mechanism is used to generate power by converting the
mechanical energy generated by a vehicle going up on a speed breaker into
electrical energy. Producing electricity from a speed breaker is a new concept
that is undergoing research. The number of vehicles on road is increasing
rapidly and if we convert some of the kinetic energy of these vehicles into the
rotational motion of roller then we can produce considerable amount of
electricity, this is the main concept of this project.

Power generation using speed breakers

1.1BASIC MECHANISMS:
This project is done by using three different mechanisms. They are:
1. Roller mechanism
2. Rack- Pinion mechanism
3. Crank-shaft mechanism
1.1.1Roller Mechanism:
This mechanism comprises a support element and a drive
sprocket which is rotatable, mounted on the support element for transmitting
rotational movement to a blind supporting member and a manually-movable
elongate flexible drive element which includes a plurality of interlinked toothengaging elements, and the drive sprocket including a plurality of toothengaging elements of the flexible drive element.

Fig 1.1.1(a) Roller mechanism setup

Power generation using speed breakers

Roller mechanism has some different disadvantages. Maintenance will be very

difficult and might cause collision.
The rotor (rotating shaft) is directly connected to the prime mover and rotates
as the prime mover turns. The rotor contains a magnet that, when turned,
produces a moving or rotating magnetic field. The rotor is surrounded by a
stationary casing called the stator, which contains the wound copper coils or
windings. When the moving magnetic field passes by these windings,
electricity is produced in them.
In roller blind mechanism a radial extent of the teeth of the drive sprocket is
equal to or greater than a maximum dimension of the tooth-engaging elements
of the flexible drive element. And the radial extent is equal to or greater than
twice the maximum dimension of the tooth-engaging elements of the flexible
drive element. The teeth of the drive sprocket flex in a circumferential direction
of the sprocket.

Fig 1.1.1(b) Roller mechanism

Power generation using speed breakers

1.1.2Rack And Pinion Mechanism:

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.
The Kinetic energy of moving vehicles can be converted into mechanical
energy of the shaft through rack and pinion mechanism. This shaft is connected
to the electric dynamo and it produces electrical energy proportional to traffic
density. This generated power can be regulated by using zenor diode for
continuous supply .All this mechanism can be housed under the dome like
speed breaker, which is called hump.
The generated power can be used for general purpose like streetlights, traffic
signals. The electrical output can be improved by arranging these power humps
in series and this generated power can be amplified and stored by using
different electric devices. The maintenance cost of hump is almost nullified. By
adopting this arrangement, we can satisfy the future demands to some extent.

Fig 1.1.2 Rack and pinion mechanism

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Power generation using speed breakers

1.1.3 Crank Shaft Mechanism:

A crank is an arm attached at right angles to a rotating shaft by
which reciprocating motion is imparted to or received from the shaft. It is used
to

convert circular

motion into

reciprocating

motion,

or

sometimes

reciprocating motion into circular. The arm may be a bent portion of the shaft,
or a separate arm attached to it. Attached to the end of the crank by a pivot is a
rod, usually called a connecting rod. The end of the rod attached to the crank
moves in a circular motion, while the other end is usually constrained to move
in a linear sliding motion, in and out.
The crankshaft is a mechanism that transforms rotary movement into linear
movement, or vice versa. For example, the motion of the pistons in the engine
of a car is linear (they go up and down). But the motion of the wheels has to be
rotary. So, engineers put a crankshaft between the engine and the transmission
to the wheels. The pistons of the engine move the crankshaft and the movement
becomes rotary. Then the rotary movement goes past the clutch and the gear
box, all the way to the wheels.

Fig 1.1.3 Crank shaft mechanism

In this project we selected Rack and Pinion mechanism because RackPinion assembly gives good mounting convenience and Maximum gear losses
are up to 3 to 5%,Efficiency 95%. In crankshaft mechanism , Crank-shafts are
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Power generation using speed breakers

required to be mounted on bearings which creates balancing problem leading to

mechanical vibrations which in turn damage the bearings. In roller mechanism
Maintenance will be very difficult and Might cause collision between rollers
and gears

CHAPTER - 2
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Power generation using speed breakers

COMPONENTS AND DESCRIPTION

The block diagram of the speed breaker using power generation is shown in
figure. The main components of this project are,
2.1 Speed Brake arrangement
2.2 Rack and pinion arrangement
2.3 Sprocket and chain Drive
2.4 Fly wheel
2.5 D.C generator
2.6 Battery
2.7 Inverter and
2.8 Light Arrangement

2.1 SPEED BRAKE ARRANGEMENT:

This is made up of mild steel. The complete set up is fixed in a box. The two Langles frame is fixed in the above two ends of the box. Bellow this L-angle
window, the actual speed brake arrangement is constructed. This L-angle
window pushes the speed brake when the time of vehicle moving on these
arrangement.
BLOCK DIAGRAM

SPEED
BRAKE

RACK & PINION AND

CHAIN SPROCKET
ARRANGEMENT

DC
GENERATOR

BATTERY

INVERTE
R

LIGHT
LOAD

Fig 2.1 Speed breaker arrangement

2.2RACK AND PINION ARRANGEMENT:

Power generation using speed breakers

The block is the important part of the unit as it houses the rack and pinion. This
rack and pinion attachment gives the rotary motion to the chain sprocket. This
block converts linear motion into rotary motion.
Rack and pinion gear system is used to transmit rotary motion into linear
motion. The rack is a portion of a gear having an infinite pitch diameter and the
line of action is tangent to the pinion.
Pinion:
This is a gear wheel which is provided to get mesh with rack to convert the
linear motion into rotary motion. They are made up of Cast iron. Type of gear
is spur gear.
A gear is a rotating machine part having cut teeth, or cogs, which mesh with
another toothed part in order to transmit torque. Two or more gears working in
tandem

are

called

a transmission and

can

produce

a mechanical

advantage through a gear ratio and thus may be considered a simple machine.
Spur gears are the most common type of gears. They have straight teeth, and
are mounted on parallel shafts. Tooth type is primarily rolling with sliding
during engagement and disengagement. some noise is normal. but it becomes
objectionable at high speeds.

Rack:
Rack teeth are cut horizontally about the required length. This is made up of
Cast iron. Rack is having infinite pitch circle diameter.

2.3 BEARINGS:

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Power generation using speed breakers

A bearing is any of various machine elements that constrain the relative motion
between two or more parts to only the desired type of motion. This is typically
to allow and promote freerotation around a fixed axis or free linear movement;
it

may

also

be

to prevent any

motion,

such

as

by

controlling

the vectors of normal forces. Bearings may be classified broadly according to

the motions they allow and according to their principle of operation, as well as
by the directions of applied loads they can handle.
In this project we used ball bearings. A ball bearing is a type of rolling-element
bearing that uses balls to maintain the separation between the bearing races.
The purpose of a ball bearing is to reduce rotational friction and
support radial and axial loads. It achieves this by using at least two races to
contain the balls and transmit the loads through the balls. In most applications,
one race is stationary and the other is attached to the rotating assembly (e.g., a
hub or shaft). As one of the bearing races rotates it causes the balls to rotate as
well. Because the balls are rolling they have a much lower coefficient of
friction than if two flat surfaces were rotating on each other.
Ball bearings tend to have lower load capacity for their size than other kinds of
rolling-element bearings due to the smaller contact area between the balls and
races. However, they can tolerate some misalignment of the inner and outer
races.
The calculated life for a bearing is based on the load it carries and its operating
speed. The industry standard usable bearing lifespan is inversely proportional
to the bearing load cubed.
If a bearing is not rotating, maximum load is determined by force that causes
non-elastic deformation of balls. If the balls are flattened, the bearing does not
rotate. Maximum load for not or very slowly rotating bearings is called "static"
maximum load. If that same bearing is rotating, that deformation tends to knead
the ball into roughly a ball shape, so the bearing can still rotate, but if this
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Power generation using speed breakers

continues for a long time, the ball fails due to metal fatigue. Maximum load for
rotating bearing is called "dynamic" maximum load, and is roughly two or
three times as high as static maximum load.
If a bearing is rotating, but experiences heavy load that lasts shorter than one
revolution, static maximum load must be used in computations, since the
bearing does not rotate during the maximum load.

Fig 2.3 Ball bearing

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Power generation using speed breakers

2.4 SPROCKET AND CHAIN DRIVE:

This is a cycle chain sprocket. The chain sprocket is coupled with another
generator shaft. The chain converts rotational power to pulling power, or
pulling power to rotational power, by engaging with the sprocket.
The sprocket looks like a gear but differs in three important ways:
1. Sprockets have many engaging teeth; gears usually have only one or two.
2. The teeth of a gear touch and slip against each other; there is basically no
slippage in a sprocket.
3. The shape of the teeth is different in gears and sprockets.

Fig 2.4 (a) Types of Sprockets

Engagement with Sprockets:
Although chains are sometimes pushed and pulled at either end by cylinders,
chains are usually driven by wrapping them on sprockets. In the following
section, we explain the relation between sprockets and chains when power is
transmitted by sprockets.
Back tension:
The relationship between flat belts and pulleys is explained below. Figure
2.4(b) shows a rendition of a flat belt drive. The circle at the top is a pulley, and
the belt hangs down from each side. When the pulley is fixed and the left side
of the belt is loaded with tension (T0), the force needed to pull the belt down to
the right side will be:
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Power generation using speed breakers

T1 = T0 3 eu
For example, T0 = 100 N: the coefficient of friction between the belt and
pulley, = 0.3;
the wrap angle u = (180).
T1 = T0 3 2.566 = 256.6 N
In brief, when you use a flat belt in this situation, you can get 256.6 N of drive
power only when there is 100 N of back tension.
For elements without teeth such as flat belts or ropes, the way to get more drive
power is to increase the coefficient of friction or wrapping angle. If a
substance, like grease or oil, which decreases the coefficient of friction, gets
onto the contact surface, the belt cannot deliver the required tension.
In the chain's case, sprocket teeth hold the chain roller. If the sprocket tooth
configuration is square, as in Figure 2.4(c), the direction of the tooth's reactive
force is opposite the chain's tension, and only one tooth will receive all the
chain's tension. Therefore, the chain will work without back tension.

Fig. 2.4(b) Flat Belt Drive

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Power generation using speed breakers

Fig. 2.4 (c) Simplified Roller/Tooth Forces

Fig. 2.4 (d) The Balance of Forces Around the Roller

But actually, sprocket teeth need some inclination so that the teeth can engage
and slip off of the roller. The balances of forces that exist around the roller are
shown in Figure 2.4(d) , and it is easy to calculate the required back tension.
For example, assume a coefficient of friction = 0, and you can calculate the
back tension (Tk) that is needed at sprocket tooth number k with this formula:
Tk = T0 3 sin (k-1) sin( + 2b)
Where:
Tk
T0

N
2b
k

=
=
=
=
=
=

back tension at tooth k

chain tension
sprocket minimum pressure angle 17 64/N()
number of teeth
sprocket tooth angle (360/N)
the number of engaged teeth (angle of wrap 3 N/360); round down to the
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Power generation using speed breakers

nearest whole number to be safe

By this formula, if the chain is wrapped halfway around the sprocket, the back
tension at sprocket tooth number six is only 0.96 N. This is 1 percent of the
amount of a flat belt. Using chains and sprockets, the required back tension is
much lower than a flat belt.
Comparison between chains - sprockets and toothed-belt back tension:
Although in toothed belts the allowable tension can differ with the number of
pulley teeth and the revolutions per minute (rpm), the general recommendation
is to use 1/3.5 of the allowable tension as the back tension (F). This is shown in
below Figure 2.8. Therefore, our 257 N force will require 257/3.5 = 73 N of
back tension.
Both toothed belts and chains engage by means of teeth, but chain's back
tension is only 1/75 that of toothed belts.

Figure 2.4(e) Back Tension on a Toothed Belt

Chain wear and jumping sprocket teeth:

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Power generation using speed breakers

The key factor causing chain to jump sprocket teeth is chain wear elongation
Because of wear elongation, the chain creeps up on the sprocket teeth until it
starts jumping sprocket teeth and can no longer engage with the sprocket.
Figure 2.4(f) shows sprocket tooth shape and positions of engagement. Figure
2.4(g) shows the engagement of a sprocket with an elongated chain.
In Figure 2.4(f) there are three sections on the sprocket tooth face:
a: Bottom curve of tooth, where the roller falls into place;
b: Working curve, where the roller and the sprocket are working together;
c: Where the tooth can guide the roller but can't transmit tension. If the roller,
which should transmit tension, only engages with C, it causes jumped
sprocket teeth.
The chain's wear elongation limit varies according to the number of sprocket
teeth and their shape, as shown in Figure 2.4(h). Upon calculation, we see that
sprockets with large numbers of teeth are very limited in stretch percentage.
Smaller sprockets are limited by other harmful effects, such as high vibration
and decreasing strength; therefore, in the case of less than 60 teeth, the stretch
limit ratio is limited to 1.5 percent (in transmission chain).

Fig.2.4(f) Sprocket Tooth Shape and Positions of Engagement

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Power generation using speed breakers

Fig. 2.4(g) The Engagement Between a Sprocket and

an Elongated Chain

Fig.2.4(h) Elongation Versus the Number of Sprocket Teeth

In conveyor chains, in which the number of working teeth in sprockets is less

than transmission chains, the stretch ratio is limited to 2 percent. Large pitch
conveyor chains use a straight line in place of curve B in the sprocket tooth
face.
A chain is a reliable machine component, which transmits power by means of
tensile forces, and is used primarily for power transmission and conveyance
systems. The function and uses of chain are similar to a belt. There are many
kinds of chain. It is convenient to sort types of chain by either material of
composition or method of construction.

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Power generation using speed breakers

We can sort chains into five types:

Cast iron chain.
Cast steel chain.
Forged chain.

Steel chain.

Plastic chain.

Demand for the first three chain types is now decreasing; they are only used in
some special situations. For example, cast iron chain is part of water-treatment
equipment; forged chain is used in overhead conveyors for automobile
factories. steel chain," especially the type called "roller chain," which makes
up the largest share of chains being produced, and "plastic chain." For the most
part, we will refer to "roller chain" simply as "chain."
NOTE: Roller chain is a chain that has an inner plate, outer plate, pin, bushing,
and roller.
chains according to their uses, which can be broadly divided into six types:
1. Power transmission chain.
2. Small pitch conveyor chain.
3. Precision conveyor chain.
4. Top chain.
5. Free flow chain.

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Power generation using speed breakers

6. Large pitch conveyor chain.

The first one is used for power transmission; the other five are used for
conveyance. there are special features in the composition of precision conveyor
chain, top chain, and free flow chain.

Basic Structure of Power Transmission Chain

A typical configuration for RS60-type chain is shown in Figure 2.4.2

Fig. (2.4.2.) The Basic Components of Transmission Chain

Connecting link :
This is the ordinary type of connecting link. The pin and link plate are slip fit in
the connecting link for ease of assembly. This type of connecting link is 20
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Power generation using speed breakers

percent lower in fatigue strength than the chain itself. There are also some
special connecting links which have the same strength as the chain itself.

Tap Fit Connecting Link In this link, the pin and the tap fit connecting link
plate are press fit. It has fatigue strength almost equal to that of the chain itself.

Fig. 2.4.2 (b)

Standard Connecting Link
(top)
Offset Link
and Tap Fit Connecting Link
(bottom)
An offset link is used
when an odd number of
chain links is required. It is
35 percent lower in fatigue
strength than the chain itself.
The pin and two plates are
slip fit. There is also a two-pitch offset link available that has fatigue strength
as great as the chain itself.

Fig. 2.4.2(c) Offset Link

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Power generation using speed breakers

2.5 FLY WHEEL:

A flywheel is a rotating mechanical device that is used to store rotational
energy. Flywheels have a significant moment of inertia, and thus resist
changes in rotational speed. The amount of energy stored in a flywheel is
proportional to the square of its rotational speed. Energy is transferred to a
flywheel by applying torque to it, thereby increasing its rotational speed, and
hence its stored energy. Conversely, a flywheel releases stored energy by
applying torque to a mechanical load, thereby decreasing its rotational speed.

Three common uses of a flywheel include:

They provide continuous energy when the energy source is

discontinuous. For example, flywheels are used in reciprocating engines
because the energy source, torque from the engine, is intermittent.

They deliver energy at rates beyond the ability of a continuous energy

source. This is achieved by collecting energy in the flywheel over time and
then releasing the energy quickly, at rates that exceed the abilities of the
energy source.
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Power generation using speed breakers

They control the orientation of a mechanical system. In such

applications, the angular momentum of a flywheel is purposely transferred
to a load when energy is transferred to or from the flywheel.

Flywheels are typically made of steel and rotate on conventional bearings;

these are generally limited to a revolution rate of a few thousand RPM. A
rotating flywheel responds to any momentum that tends to change the direction
of its axis of rotation by a resulting precession rotation.
Fly wheel is used to increase the rpm of the system. The generator is coupled
with this shaft, so that increase the RPM of the generator.
2.6 PERMANENT MAGNET D.C. GENERATOR

A generator is a device that converts mechanical energy to electrical energy. A

generator forces electric charge (usually carried by electrons) to flow through
an external electrical circuit.
Voltage Production
DC Circuits, that there are three conditions necessary to induce a voltage into a
conductor.
1. A magnetic field
2. A conductor
3. Relative motion between the two.
A DC generator provides these three conditions to produce a DC voltage
output.
Theory of Operation
A basic DC generator has four basic parts:
(1) A magnetic field;
(2) A single conductor, or loop;
(3) A commutator; and
(4) Brushes
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Power generation using speed breakers

The magnetic field may be supplied by either a permanent magnet or an

electromagnet. For now, we will use a permanent magnet to describe a basic
DC generator.
Basic Operation of a DC Generator A single conductor, shaped in the form of a
loop, is positioned between the magnetic poles. As long as the loop is
stationary, the magnetic field has no effect (no relative motion). If we rotate
the loop, the loop cuts through the magnetic field, and an EMF (voltage) is
induced into the loop.

Fig 2.6 Generator construction

When we have relative motion between a magnetic field and a conductor in
that magnetic field, and the direction of rotation is such that the conductor cuts
the lines of flux, an EMF is induced into the conductor. The magnitude of the
induced EMF depends on the field strength and the rate at which the flux lines
are cut.
The stronger the field or the more flux lines cut for a given period of time, the
larger the induced EMF.
Eg = KFN

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Power generation using speed breakers

where Eg = generated voltage

K

= fixed constant

= magnetic flux strength

= speed in RPM

Direction of the induced current flow can be determined using the "lefthand rule" for generators. This rule states that if you point the index finger of
your left hand in the direction of the magnetic field (from North to South) and
point the thumb in the direction of motion of the conductor.
For example, the conductor closest to the N pole is traveling upward across the
field; therefore, the current flow is to the right, lower corner. Applying the
left-hand rule to both sides of the loop will show that current flows in a
counter-clockwise direction in the loop.
DC GENERATOR CONSTRUCTION

Output Voltage-vs-Load Current for Shunt-Wound DC Generator the shuntwound generator, running at a constant speed under varying load conditions,
has a much more stable voltage output than does a series-wound generator.
Some change in output voltage does take place. This change is caused by the
fact that, as the load current increases, the voltage drop (I R) across the
armature coil increases, causing output voltage to decrease.
As a result, the current through the field decreases, reducing the magnetic field
and causing voltage to decrease even more. If load current is much higher than
the design of the generator, the drop in output voltage is severe. For load
current within the design range of the generator, the drop in output voltage is
minimal.

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Power generation using speed breakers

2.7BATTERY
Batteries seem to be the only technically and economically available storage
means. Since both the photo-voltaic system and batteries are high in capital
costs. It is necessary that the overall system be optimized with respect to
available energy and local demand pattern. To be economically attractive the
storage of electricity requires a battery with a particular combination of
properties:
(1)

Low cost

(2)

Long life

(3)

High reliability

(4)

High overall efficiency

(5)

Low discharge

(6)

Minimum maintenance

We use lead acid battery for storing the electrical energy for lighting the street
and so about the lead acid cells are explained below.
LEAD-ACID WET CELL:

Where high values of load current are necessary, the lead-acid cell is the type
most commonly used. The electrolyte is a dilute solution of sulfuric acid
(HSO). In the application of battery power to start the engine in an auto
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Power generation using speed breakers

mobile, for example, the load current to the starter motor is typically 200 to
400A. One cell has a nominal output of 2.1V, but lead-acid cells are often used
in a series combination of three for a 6-V battery and six for a 12-V battery.
The lead acid cell type is a secondary cell or storage cell, which can be
recharged. The charge and discharge cycle can be repeated many times to
restore the output voltage, as long as the cell is in good physical condition.
However, heat with excessive charge and discharge currents shortens the useful
life to about 3 to 5 years for an automobile battery. Of the different types of
secondary cells, the lead-acid type has the highest output voltage, which allows
fewer cells for a specified battery voltage.
CONSTRUCTION:
Inside a lead-acid battery, the positive and negative electrodes consist of a
group of plates welded to a connecting strap. The plates are immersed in the
electrolyte, consisting of 8 parts of water to 3 parts of concentrated sulfuric
acid. Each plate is a grid or framework, made of a lead-antimony alloy.

Fig 2.7 Lead acid Battery

CHEMICAL ACTION:
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Power generation using speed breakers

Sulfuric acid is a combination of hydrogen and sulfate ions. When the cell
discharges, lead peroxide from the positive electrode combines with hydrogen
ions to form water and with sulfate ions to form lead sulfate. Combining lead
on the negative plate with sulfate ions also produces he sulfate.
Therefore, the net result of discharge is to produce more water, which dilutes
the electrolyte, and to form lead sulfate on the plates. As the discharge
continues, the sulfate fills the pores of the grids, retarding circulation of acid in
the active material. Lead sulfate is the powder often seen on the outside
terminals of old batteries. When the combination of weak electrolyte and
sulfating on the plate lowers the output of the battery, charging is necessary.
On charge, the external D.C. source reverses the current in the battery. The
reversed direction of ions flows in the electrolyte result in a reversal of the
chemical reactions. Now the lead sulfates on the positive plate reactive with
the water and sulfate ions to produce lead peroxide and sulfuric acid. This
action re-forms the positive plates and makes the electrolyte stronger by adding
sulfuric acid.
At the same time, charging enables the lead sulfate on the negative plate to
react with hydrogen ions; this also forms sulfuric acid while reforming lead on
the negative plate to react with hydrogen ions; this also forms currents can
restore the cell to full output, with lead peroxide on the positive plates, spongy
lead on the negative plate, and the required concentration of sulfuric acid in the
electrolyte.
The chemical equation for the lead-acid cell is

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Power generation using speed breakers

Fig.2.7 (a) chemical action of battery

Charge
Pb + pbO + 2HSO

2pbSO + 2HO
Discharge

On discharge, the pb and pbo combine with the SO ions at the left side of the
equation to form lead sulfate (pbSO) and water (HO) at the right side of the
equation. One battery consists of 6 cells, each have an output voltage of 2.1V,
which are connected in series to get an voltage of 12V and the same 12V
battery is connected in series, to get an 24 V battery. They are placed in the
water proof iron casing box.
CURRENT RATINGS:
Lead-acid batteries are generally rated in terms of how much discharge currents
they can supply for a specified period of time; the output voltage must be
maintained above a minimum level, which is 1.5 to 1.8V per cell. A common
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Power generation using speed breakers

rating is ampere-hours (A.h.) based on a specific discharge time, which is often

8h. Typical values for automobile batteries are 100 to 300 A.h.
As an example, a 200 A.h battery can supply a load current of 200/8 or 25A,
used on 8h discharge. The battery can supply less current for a longer time or
more current for a shorter time. Automobile batteries may be rated for cold
cranking power, which is related to the job of starting the engine. A typical
rating is 450A for 30s at a temperature of 0 degree F.
Note that the ampere-hour unit specifies coulombs of charge. For instance, 200
A.h. corresponds to 200A*3600s (1h=3600s).

the equals 720,000 A.S, or

coulombs. One ampere-second is equal to one coulomb. Then the charge

equals 720,000 or 7.2*10^5C. To put this much charge back into the battery
would require 20 hours with a charging current of 10A.
The ratings for lead-acid batteries are given for a temperature range of 77 to
80F. Higher temperature increase the chemical reaction, but operation above
110F shortens the battery life.
Low temperatures reduce the current capacity and voltage output. The amperehour capacity is reduced approximately 0.75% for each decreases of 1 F below
normal temperature rating. At 0F the available output is only 60 % of the
ampere-hour battery rating.
In cold weather, therefore, it is very important to have an automobile battery
unto full charge. In addition, the electrolyte freezes more easily when diluted
by water in the discharged condition.
An external D.C. voltage source is necessary to produce current in one
direction. Also, the charging voltage must be more than the battery e.m.f.
Approximately 2.5 per cell are enough to over the cell e.m.f. so that the
charging voltage can produce current opposite to the direction of discharge
current.

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Power generation using speed breakers

The reversal of current is obtained just by connecting the battery VB and

charging source VG with + to + and to-, as shown in figure. The charging
current is reversed because the battery effectively becomes a load resistance for
VG when it higher than VB. In this example, the net voltage available to
produce charging currents is 15-12=3V.
A commercial charger for automobile batteries is essentially a D.C. power
supply, rectifying input from the AC power line to provide D.C. output for
charging batteries. Float charging refers to a method in which the charger and
the battery are always connected to each other for supplying current to the load.
In figure the charger provides current for the load and the current necessary to
keep the battery fully charged. The battery here is an auxiliary source for D.C.
power.
It may be of interest to note that an automobile battery is in a floating-charge
circuit. The battery charger is an AC generator or alternator with rectifier
diodes, driver by a belt from the engine. When you start the car, the battery
supplies the cranking power. Once the engine is running, the alternator charges
he battery. It is not necessary for the car to be moving. A voltage regulator is
used in this system to maintain the output at approximately 13 to 15 V.
The constant voltage of 24V comes from the solar panel controlled by the
charge controller so for storing this energy we need a 24V battery so two 12V
battery are connected in series. It is a good idea to do an equalizing charge
when some cells show a variation of 0.05 specific gravity from each other.
This is a long steady overcharge, bringing the battery to a gassing or bubbling
state. Do not equalize sealed or gel type batteries. With proper care, lead-acid
batteries will have a long service life and work very well in almost any power
system. Unfortunately, with poor treatment lead-acid battery life will be very
short.

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Power generation using speed breakers

2.8INVERTER
The process of converting D.C. into A.C. is known as INVERSION. In other
words, we may define it as the reverse process of rectification. The device,
which performs this process, is known as an INVERTOR. Inversion is, by no
means, a recent process. In olden days gas-filled tubes and vacuum tubes were
used to develop inverters. Thyratron inverter is popularly used as a large
power device. Vacuum tube inverters were generally used for high-frequency
applications.

Some of the main disadvantages of the tube as well as the

mercury pool type inverters are:

1.

They are very costly

2.

They are very big in size and heavy in weight

3.

They have very poor efficiency

4.

The voltage drop across these devices is very high

5.

They are less accurate

6.

They are very slow in response, etc.

The basic principle of an inverter can be explained with the help of a simple
circuit, as shown in figure. If switch S is connected alternately to position 1 and
2 at a rapid speed and if S is not kept closed to any of the two positions (1 and
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Power generation using speed breakers

2) for too long, and then an alternating voltage will appear across the primary
winding. This can be explained by the direction of the current flow in the
primary winding.
Although the voltage applied is D.C. in nature, the direction of current flow in
the primary winding when S is connected to position 1 is from top to bottom
whereas when S is connected at position 2, the current flows from bottom to
top. This change in the direction of current flow in the primary winding gives
rise to an alternating voltage in it. The frequencies of this alternating voltage
will depend on how rapidly the switch (S) positions are interchanged. This
alternating voltage in the primary winding will induce an alternating emf in the
secondary winding, which will act as the A.C. output.
With the development of semi-conductor devices, a lot of improvements to
took place in the design of inverter circuits. Transistor being a fast-switching
device was used as a switch for developing low and medium power inverters.
CIRCUIT DIAGRAM

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Power generation using speed breakers

2.9 FLUORESCENT TUBES

This type of lamp is a low-pressure mercury vapor discharge lamp. Fluorescent
lighting has a great advantage over other light source in many applications. It
is possible to achieve quite high lighting intensities without excessive
temperature rises. The efficiency of fluorescent lamp is about 40 lumens per
watt, about three times the efficiency of an equivalent tungsten lamp. The
average life of a fluorescent lamp is about 4,000 working hours.

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Power generation using speed breakers

CONSTRUCTION:

The fluorescent tube consists of a glass tube and 0.6 meter, 1.2 meters and 1.5
meters in length. The inside surface of the tube is coated with a thin layer of
fluorescent material in the form of a powder. Various fluorescent materials
give different color light. By mixing the various powders light of any desired
color including daylight can be obtained.
The glass tube of the fluorescent lamp is provided at both ends with bipin caps
and oxide coated tungsten filaments. The tube contains organ gas with a small
quantity of mercury under low pressure. Even with organ gas the discharge
will not start at ordinary main voltage. A choke and a starter switch are
therefore incorporated in the circuit of the tube lamp to give a momentary high
voltage across the tube to start the discharge. The choke is connected in series
with the tube the starter is connected across tube.
The circuit is suddenly opened at the starter, the flux around the choke collapse
causing a kick of about 1000V.

This voltage is applied across the two

electrodes and sufficient to start the discharge of the tube. During the steady
operation of this lamp the voltage across the tube drops to about 150 volts.
This voltage is sufficient to maintain the discharge of the tube.
During the steady operation of this lamp, the voltage across the tube drops to
about 150 volts. This voltage is sufficient to maintain the discharge. The
choke in series with the tube now acts as a stabilizer. A capacitor is connected
across the circuit it improve the power factor.
WORKING OF FLUROSCENT TUBE:
The glow starter is a voltage operated type, which is enclosed in a glass bulb
filled with a mixture of helium, and hydrogen is neon or argon. One of the
electrodes is a bimetallic strip. Normally the contacts are open.

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Power generation using speed breakers

When the supply is switched on the potential across the bimetallic electrodes
causes a small glow discharge at a small current not enough to heat up the tube
electrodes. The discharge is enough to heat the bimetallic strips of the switch
causing them to bend and make contact. Now the tube electrodes get preheated
due to flow of large current and the gas in the immediate neighborhood is
ionized. After one or two seconds the bimetallic strips cool down and the
contacts open. This opening of contact in series with the choke causes a
momentary high voltage, which is sufficient to start the discharge in the main
tube.
After the establishment of discharge between the two electrodes, voltage
required to maintain the same is small. As the lamp current flows through the
choke, sufficient voltage drop occurs; they are by allowing only the required
voltage to be applied across the lamp.
It is, therefore, seen that choke performs two functions.

1)

It provides

inductive voltage surge to start the discharge. 2) When the lamp is working, it
limits the current in the lamp circuit. Now the voltage available across the
starter is not in a opposition to initiate discharge between its bimetallic
electrodes. A condenser of 0.05mf is put in series with a 100-ohm resistor and
connected across the stator terminal. The checks any condenser surge and
prevents stator contacts from being welded together and minimize radio
interference also the condenser helps to induce high voltage across the choke
by the sudden interruption of current through the stator circuit when the straight
bimetallic strip gets opened.
The power factor of the lamp is about 0.5 due to the presence of choke.
Condenser connected across the supply improves the power factor to 0.95. The
fluorescent powders used in the case of low-pressure lamps are solids and are
usually called as phosphors. By the use of suitable mixtures of phosphors a
variety of colour can be obtained.

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Power generation using speed breakers

CHAPTER-3
DESIGN CALCULATIONS
3.1 DESIGN OF PINION

From PSG design data book (page no.7.18)

dmin > (0.59/ cmax) [[Mt]/((1/E1)+(1/E2)) 2](1/3 _________________ (1)
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Power generation using speed breakers

Where,
cmax = maximum contact compressive stress N/m2
E1, E2 = Youngs modulus N/m2
Mt = Torque N-m
E1 = E2 = 1.1106 N/m2
Calculation of cmax

cmax = HB CB Kcl

________________

(2)

Where,
HB = Brinell hardness number
CB = coefficient depends on hardness
Kcl

= life factor
Kcl = {[1 x 107]/N} 1/6
N

_______________

(3)

= 60 x n x T

Where,
N

= rpm

= life in no. Of cycles

= life in hours.
= 8000 hours.

From P.S.G design data book (page no.2.4),

CB = 20
HB = 200
Substituting the values of N, n, T in the equation [3],
The value of kcl is obtained as 1.139.
Kcl = 1.139.

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Power generation using speed breakers

Substituting the values in equation [2]

cmax

= 20 x 200 x 1.1309
= 4520 x105 N/m2

Calculation of Mt
Mt = 97420 x (Kw/n).

____________

(4)

____________

(5)

For power calculation

Centrifugal force, fc

= m 2 r

= 7kg

=mxg

= 2n/60

= 1m

Substituting the values of m, , r in equation [4]

fc
Downward force, fd

= 7.56 N.
= mxg
= 7 x 9.81
= 68.6N.

Centrifugal force,

f = fc + fd
= 68.6 + 7.56
=

76.17N

Torque = f x r = 76.17 x 1
= 76.2Nm.
Power = Torque x angular velocity.
= 76.2 x 1.05
= 79.7w
Substituting the value of kw and n in equation in [3],
Mt = 776.7
[Mt] = 1.4 x Mt
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Power generation using speed breakers

= 1.4 x 776.7
= 1087.1 N-m
Substituting the values of cmax, [Mt], E1,E2

in equation [1],

The minimum diameter of the pinion is calculated to be 76.7mm.

We have taken the standard diameter of pinion as 75mm.
Specification Of Pinion
Material

: cast-iron

Outside diameter

: 75mm

Circular pitch

: 4.7mm

Tooth depth

: 3.375mm

Module

: 1.5mm

Pressure angle

: 21

Pitch circle diameter

: 72mm

Addendum

: 1.5mm

Dedendum

: 1.875mm

Circular tooth Thickness

: 2.355mm

Fillet radius

: 0.45mm

Clearance

: 0.375mm

Design of rack
Pitch circle diameter of the gear is = 72mm
Circumference of the gear is

= pitch circle diameter

= 72
= 226mm

The dimension is for 360 rotation

For 180rotation the rack length is 113 mm
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Power generation using speed breakers

Specification Of Rack
Material

: cast iron

Module

: 1.5mm

Cross-section

:7525mm

Teeth on the rack is adjusted for 113mm

3.2 Design of Springs:
Assume that spring material as chrome vanadium spring steel because it is very
efficient at high stresses and at high temperatures.
Assume spring index as 6,it lies b/w 3-12
Standard wire diameter as 3 mm
C=8
d=3mm
spring index C is defined as the ratio of mean diameter of spring coil to the
wire diameter
C= D/d
By this we can calculate spring coil diameter(D)
D=24mm.
Max allowable stress from the below graph is 550 MPa.

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Power generation using speed breakers

Fig 3.3 SAE 1065 spring steel max allowable stress(MPa)

Calculated stress (f):
Helical springs are stressed in torsional and bending.
Torsional shear stress:
f=8FD/(d^3)
=146.22 MPa
because there is bending as well as torsion, the combined stress
is greater than torsional shear stress only.
Combined stress fc= Ks *f
Ks is Wahl factor

Ks

0.615 4 c1
+
c
4 c4

Ks= 1.2525

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Power generation using speed breakers

fc= 183.145 MPa

K= F/x
K is spring constant and x is deflection
x= 30mm
K= 147.15/30
=4.905
No of coils = na= Gd/(8c^3 K)
=17.5= 18
For compression springs n= na+2 = 20
Solid length Ls = d*n = 80 mm
Xallow = 15% x
= 4.5 mm
Total length = L = Ls +X+Xallow
= 114.5 mm
Buckling:
For steel, critical length = 2.57 *D/Ce
Ce is spring seat configuration
Assume Ce as 0.5
Critical length = 128.5 mm > 114.5 mm
The design is safe.

3.4 OUTPUT POWER CALCULATION:

Let us consider,
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Power generation using speed breakers

The mass of a body

60 Kg (Approximately)

Height of speed brake

10 cm

Work done

Force x Distance

Weight of the Body

60 Kg x 9.81

588.6 N

Height of the speed brake

10 cm

0.10 m

Work done/Sec

(588.6 x 0.10)/60

0.98 Watts

Here,
Force

Distance traveled by the body

Output power

(For One pushing force)

However, this much power produced, it cannot be tapped fully. From the
above purpose we have select to generate electricity by permanent magnet type
D.C generator and store it by 12V lead-acid battery cell.

CHAPTER - 4
DRAWINGS
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Power generation using speed breakers

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Power generation using speed breakers

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Power generation using speed breakers

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Power generation using speed breakers

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Power generation using speed breakers

CHAPTER-5
WORKING PRINCIPLE

The complete diagram of the power generation using speed brake is given
below. L-angle window is inclined in certain small angle which is used to
generate the power. The pushing power is converted into electrical energy by
proper driving arrangement.
The rack & pinion, spring arrangement is fixed at the speed brake which is
mounded bellow the L-angle window. The spring is used to return the inclined
L-angle window in same position by releasing the load. The pinion shaft is
connected to the supporter by end bearings as shown in fig. The larger sprocket
also coupled with the pinion shaft, so that it is running the same speed of
pinion. The larger sprocket is coupled to the small cycle sprocket with the help
of chain (cycle).
This larger sprocket is used to transfer the rotation force to the smaller
sprocket. The smaller sprocket is running same direction for the forward and
reverse direction of rotational movement of the larger sprocket. This action
locks like a cycle pedaling action.
The fly wheel and gear wheel is also coupled to the smaller sprocket shaft. The
flywheel is used to increase the rpm of the smaller sprocket shaft. The gear
wheel is coupled to the generator shaft with the help of another gear wheel.
The generator is used here, is permanent magnet D.C generator. The generated
voltage is 12Volt D.C. This D.C voltage is stored to the Lead-acid 12 Volt
battery. The battery is connected to the inverter. This inverter is used to convert
the 12 Volt D.C to the 230 Volt A.C. This working principle is already
explained the above chapter. This 230 Volt A.C voltage is used to activate the
light, fan and etc.
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Power generation using speed breakers

By increasing the capacity of battery and inverter circuit, the power rating is
increased. This arrangement is fitted in highways; the complete arrangement is
kept inside the floor level except the speed brake arrangement.

Fig 5.1 Working principle

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Power generation using speed breakers

Fig .5.2 Experimental view

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Power generation using speed breakers

CHAPTER-6
LIST OF MATERIALS

SL. NO.
1

NAME OF THE PARTS

MATERIAL
Model
Speed
brake Mild Steel

QUANTITY
1

2
3
4
5
6
7
8
9
10
11
12
13

arrangement
Spring
Bearing
Sprocket
Fly wheel
Gear wheel
Generator (D.C 12 V)
Battery (12 V)
Inverter
Chain
Rack
Pinion
Connecting Wire

4
4
2
1
2
1
1
1
1
1
1
2 meter

Steel
Steel
C.I
C.I
C.I
Aluminium
Lead-acid
Steel
M.S
M.S
Cu

CHAPTER-7
ADVANTAGES AND DISADVANTAGES

ADVANTAGES

Power generation is simply running the vehicle on this

arrangement
Power also generated by running or exercising on the brake.
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Power generation using speed breakers

No need fuel input

This is a Non-conventional system
Battery is used to store the generated power

DISADVANTAGES
The major drawback of this POWER HUMP is design of springs. When we
have less traffic and there is difficulty in design of springs also the generation
of power is intermittent, we have to smooth out this variations.
Slight inclination is required in the speed brake
Mechanical moving parts is high
Initial cost of this arrangement is high.
Care should be taken for batteries

CHAPTER - 7
COST ESTIMATION

1. MATERIAL COST:
SL.

NAME OF THE PARTS

MATERIAL

QUANTITY

NO.
1

Model speed brake

Mild Steel

AMOUNT
(RS)

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Power generation using speed breakers

arrangement (Including
2
3
4
5
6
7
8
9
10
11
12
13

Supports)
Spring
Bearing
Sprocket
Fly wheel
Gear wheel
Generator (D.C 12V)
Battery (12 V)
Inverter
Chain
Rack
Pinion
Connecting Wire

800
Steel
2
Steel
4
C.I
2
C.I
1
C.I
2
Aluminum
1
Lead-acid
1
Electronic PCB
5 meter
Steel
1
M.S
1
M.S
1
Cu
2 meter
TOTAL =7500

280
200
500
120
500
800
650
2500
100
350
350
50

2. LABOUR COST
LATHE, DRILLING, WELDING, GRINDING, POWER HACKSAW, GAS
CUTTING:
Cost Rs= 600

3. OVERHEAD CHARGES
The overhead charges are arrived by Manufacturing cost
Manufacturing Cost =
=
=
Overhead Charges =
=

Material Cost + Labour cost

7500+600
8100
20% of the manufacturing cost
1340
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Power generation using speed breakers

TOTAL COST
Total cost

Material Cost + Labour cost + Overhead Charges

9440

Total cost for this project

9440

CHAPTER-8
APPLICATIONS AND FUTURE SCOPE

APPLICATIONS:
Power generation using speed brake system can be used in most of the
places such as
All highways
All road ways Speed brake

FUTURE SCOPE:
This arrangement is slightly modified to construct in foot step and this
arrangement is fixed in
schools,
cinema theatres,
Shopping complex and
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Power generation using speed breakers

Many other buildings.

With proper improvements in design and installation, we can produce
240v/230v with 5-10A power smoothly and can be used for public use like
streetlights or traffic signals
By these improvements in design it can glow 5 streetlights of 40-watt capacity,
which will consume 2.7 K.W.H. per day.

CHAPTER-9
CONCLUSION

Energy is an important input to sustain industrial growth and standard of living

of a country and can be directly related to per-capita energy consumption. The
various types of non-conventional sources of energy are solar energy, wind
energy, biogas etc now by developing POWER HUMP we can generate
power with out utilizing any external sources mentioned earlier.
Now, vehicular traffic in big cities is more, causing a problem to human being.
But this vehicular traffic can also be utilized for power generation by means of
new technique called POWER HUMP. If it is placed in heavy traffic roads,
the weight and kinetic energy of the vehicles can be used to produce
mechanical power in shafts and this mechanical power is once again converted
into electrical energy.

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Power generation using speed breakers

As it does not utilize any external source, and traffic will never be reduced,
these power humps are more reliable, and have more life than any other power
source. It is also feasible from the customer point of view.

CHAPTER - 10
BIBLIOGRAPHY

Shakun Srivastava , Ankit Asthana JERS/Vol.II/ Issue I/April-June,

2011/163-165
Aswathaman.V IPCBEE

vol.1 (2011) (2011) IACSIT Press,

Singapore
Rai. G.D. Non Conventional Energy Sources, Khanna Publishers,
Delhi.
Ramesh. R, Udaya Kumar, K.Anandakrishnan Renewable Energy
Technologies, Narosa Publishing House, Madras.
A.K.Sawhney.

Text

Book

Of

Electrical,

Electronics,

Instrumentation And Measurements

B.L.Therja, A.K. Theraja. A Text Book Of Electrical Technology
57

Power generation using speed breakers

G.R.Nagpal. Power Plant Engineering Khanna Publishers, Delhi.

P.S.G. Data Book

58