A

Project Report

On

“Power Generation Using Speed Breaker”

Submitted in partial fulfillment on requirements of the degree of

Bachelor of Engineering in Mechanical Engineering

Submitted by
PRASHANT VILAS GAWAS 13

RUSHIKESH MAHENDRA PATIL 40

SHUBHAM CHANDRAKANTH PATIL 42

SOHAM SUDESH THUMBRE 58

Under the guidance of

Prof. Pradnya Bhondiwale

Department of Mechanical Engineering

Jai Shri Siddhivinayak Foundation

B. R. Harne College of Engineering & Technology

Karav, Vangani (W) Dist-Thane-421503

[2021-2022]

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DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE
This is to certify that the project entitled “POWER GENERATION USING SPEED
BREAKER” is a benefited work carried out as a part of their eight-semester synopsis report for
B.E Mechanical Engineering Department by the following students.

Prashant Vilas Gawas 13

Rushikesh Mahendra Patil 40
Shubham Chandrakant Patil 42
Soham Sudesh Thumbre 58

__________________________ _____________________

Prof. Pradnya Bhondiwale Name of Examiner

Supervisor/ Guide

___________________________ _____________________

Prof. Amar K Modi Dr. V.A. Patil

Head of Department (Mechanical) Principle

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Declaration

I declare that this written submission on represents our ideas in our own words and were other’s
Ideas or words have been included, we have adequately cited and referenced the original sources.
We also declare that we have adhered to all principles of academic honesty and integrity and have
not misrepresented or fabricated or falsified any idea/data/source in my submission. We
understand that any violation of the above will be cause for disciplinary action by the Institute and
can also evoke penal action from the sources which have thus not been properly cited or from
whom proper permission has not been taken when needed.

PRASHANT VILAS GAWAS 13

RUSHIKESH MAHENDRA PATIL 40

SHUBHAM CHANDRAKANTH PATIL 42

SOHAM SUDESH THUMBRE 58

Place: __________________

Date: ___________________

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 POWER GENERATION USING SPEED BREAKER

Acknowledgement

We are extremely fortunate to involved in an exciting and challenging project like “POWER
GENERATION USING SPEED BREAKER”. It has enriched our life, giving us an
opportunity to work in a field of Design Engineering.
This project increased our thinking and understanding capability and after the completion of
project, we experience the feeling of achievement and satisfaction.
We would like to express our greatest gratitude and respect to our Head of Department and
project guide Prof. Amar Kumar, project coordinator Prof. Pradnya Bhondiwale for their
excellence guidance valuable suggestion and endless support. They have not only been a
wonderful guide but also a guidance people. We consider ourselves extremely lucky to be able
to work under guidance of such a guide of such dynamic personalities. Actually, they are one of
such genuine persons for whom our words will not be enough to express.
It was impossible for us to complete our project without their help. We are also grateful to our
Principal, Dr. V.A. Patil for their encouragement. We would like to express our thanks to all
our classmates, all staffs and faculty members of mechanical engineering department who
willingly rendered us their unselfish help and support.
Last but not the least; we want to convey our heartiest gratitude to our parents for their
immeasurable love, support and encouragement.

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 POWER GENERATION USING SPEED BREAKER

ABSTRACT

Using speed bump for power generation by using gear arrangement and electronic gadgets. Large
amounts amount of electricity can be generated saving lot of money. And if implemented will be
very beneficial for Government. When vehicle is in motion it produces various forms of energy
like, due to friction between vehicle’s wheel and road i.e., rough surface heat energy is produced,
also when vehicle traveling at high speed strikes the wind. The principle involved is potential
energy to electrical energy conversion.
There is a system to generate power by converting the potential energy generated by a vehicle
going up on a speed breaker into kinetic energy. When the vehicle moves over the inclined plates,
it gains height resulting in increase in potential energy, which is wasted in a conventional rumble
strip. When the breaker comes down, they crank a lever fitted to a ratchet-wheel type mechanism
(an angular motion converter) which in turn rotates a geared shaft loaded with recoil springs. The
output of this shaft is coupled to a dynamo to convert kinetic energy into electricity. This is the
short process for Electrical power generation through speed breaker.
Keywords: Potential energy, kinematic energy, energy conversion

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Index
Title Page No.
Certificate 2
Declaration 3
Acknowledgement 4
Abstract 5
List of Figures 8

1. Chapter 1
1.1 Introduction 9

2. Chapter 2
2.1 Literature Review 13

3. Chapter 3
3.1 Problem Definition and Project Objective 16

4. Chapter 4
4.1 Methodology 17
4.1.1 Spring Mechanism 18
4.1.2 Freewheel Mechanism 19
4.1.3 Chain Drive Mechanism 20
4.1.3 Bearing Mechanism 21
4.1.3 Gear Mechanism 22

5. Chapter 5
5.1 Working 23
5.2 Manufacturing Process 24
5.2.1 Arc Welding Operation 24
5.2.2 Turning Operation 25
5.2.3 Drilling Operation 26
5.2.4 Grinding Operation 27

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Title Page No.

6. Chapter 6
6.1 Component Dimensions 28
6.2 Output of Speed Breaker 29
6.3. Components 30
6.3.1 Pedestal Bearing 30
6.3.2 Spur Gear 31
6.3.3 Shaft 32
6.3.4 Freewheel 33
6.3.5 Chain 34
6.3.6 Coil Spring 35
6.3.7 Box Frame 36
6.3.8 Nuts and Bolts 37
6.3.9 Washers 38
6.3.10 Dc Motors 39
6.3.11 Wire And LED 40

7. Chapter7
7.1 Result 41
7.2 Conclusion 42

References 43

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List of Figures
Fig. No Figure Details Page. No
1.1 Vehicle sold in FY 2016 FY 2021 10
1.2 Vehicle passing over a speed breaker 11
4.0.1 Representation of working using block diagram 17
4.1.1 Spring Anatomy 18
4.1.2 Freewheel Mechanism 19
4.1.3 Chain Drive Mechanism 20
4.1.4 Pedestal Bearing Working 21
4.1.5 Simple Gear Meshing 22
5.2.1 Basic Arc Welding Circuit Diagram 24
5.2.2 Basic Turning Operation Diagram and Bushes 25
5.2.3 Basic Drilling Operation Representation and Vertical 26
Drill Machine
5.2.4 Diagram of A Hand Grinder 27
6.3.1 Pedestal Bearing and Set Screw 30
6.3.2 Spur Gear 31
6.3.3 Shaft 32
6.3.4 Freewheel 33
6.3.5 Chain and Chain Opening 34
6.3.6 Coil Spring 35
6.3.7 Box Frame 36
6.3.8 Nut and Bolt 37
6.3.9 Washers 38
6.3.10 Dc Motors 39
6.3.11 Wire And LED 40

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CHAPTER 1

Introduction

1.1 Introduction:
In the present scenario power becomes the major need for human life. The availability and its
per capita consumptions are 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 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.
An innovative and useful concept of Generating Electricity from a Speed breaker is our step
to improve the situation of electricity. First of all, what is electricity means to us? 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

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coal burning stoves. Direct current (DC) electricity had been used in arc lights for outdoor
lighting. In the late-1800s, Nikola Tesla pioneered the generation, transmission, and use of
alternating current (AC) electricity, which can be transmitted over much greater distances than
direct current.

Vehicles sold from 2016-2021

30
25
Millions

20
15
10
5
0
1
2

2016 2017 2018 2019 2020 2021

Figure 1.1 Vehicles sold in FY2016-FY2021

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. Tesla's inventions used electricity to bring indoor
lighting to our homes and to power industrial machines. 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. There are already existing such systems using
renewable energy such as solar wind), OTEC (ocean thermal energy conversions) etc.…for
power generation. The latest technology which is used to generate the power by such renewable
energy is the” power hump”.

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The sales of vehicles in FY2016 are 20.53 million which has increased to 26.28 million in
FY2019, and decreased in year 2020 due to Covid-19 condition.
The number of vehicles on road is increasing rapidly and if we convert some of the Potential
energy of these vehicle into the rotational motion of generator then we can produce
considerable amount of electricity, this is the main concept of this project. At present we are
facing shortage of electricity.
Electricity generation was first developed in the 1800's using Faraday’s dynamo generator.
Almost 200 years later we are still using the same basic principles to generate electricity, only
on a much larger scale. Now we are throwing some light on the very new and innovative
concept i.e., generating electricity from a speed breaker. Producing electricity from a speed
breaker is a new concept that is undergoing research. India's installed capacity is nearly 20 per
cent of China's capacity though both countries have billion plus people.

Figure 1.2 Vehicle passing over a speed breaker

There is roughly 12 per cent power deficit in the peak hours. Tariffs are set by the state
governments so power firms are not allowed to pass on rising fuel costs to consumers. Banks
are burdened with loans to loss-making state-run electricity distribution firms and are unwilling
to lend to new projects that do not have assured fuel supply. India has nearly 10 per cent of the

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world's coal reserves but lack of environmental clearances and other disputes have hindered
production. Shortage of domestic supply has resulted in costlier imports. Electricity can be
generated using speed breakers, strange, isn't it? The benefits from this idea will be to generate
electricity for the streetlights, hoardings and then for other use. Generally, when vehicle is in
motion it produces various forms of energy like, due to friction between vehicle’s wheel and
road i.e., rough surface heat energy is produced, also when vehicle traveling at high speed
strikes the wind then also heat energy is produced which is always lost in environment and of
which we can’t make use of or directly we can say that all this energy that we can’t make use
of is just the wastage of energy that is abundantly available around us. In this project we are
just trying to make use of such energy in order to generate an electrical energy. This project
will work on the principle of “potential energy to electrical energy conversion” Potential
energy can be thought of as energy stored within a physical system. An innovative and useful
concept of Generating Electricity from a Speed breaker is our step to improve the situation of
electricity.

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CHAPTER 2

Literature Review

2.1 Literature Review:

From the journal paper, USING SPEED BUMP FOR POWER GENERATION
EXPERIMENTAL STUDY BY MOHAMAD RAMADANA, MAHMOUD KHALEDA B,
HICHAM EL HAGEA (SCIENCE DIRECT-APPLIED ENERGY ICTE 2015), a prototype
is constructed and an experimental study is performed. Three different masses, 41 kg, 65 kg and
80 kg, are applied on the speed-breaker systems and the produced amounts of voltages, current
and angular speed are measured. It was observed that as the mass increases the produced voltage
increases linearly. For illustration a mass of 41 kg, produces 5.0 V. This voltage reaches 15.6 V
for a mass of 65 kg and 21.5 V for a mass of 80 kg. Designing energy recovery systems that are
pollution free has become a significant goal within the research community. One of numerous
systems that have been proposed is Speed Bump Power Generation SBPG system that produces
electrical power by utilizing the movements of commuting vehicles on highways, boulevards, and
streets. Consequently, a kinetic energy is produced and transferred into electrical power. In this
paper, different types of SBPG systems are presented. An experimental analysis is performed on
the rack-and -pinion system. Results have shown that electrical power up to 45 W generated when
a mass of 80 kg is applied to SBPG system considered. Extrapolation of results confirms around
0.65 kW powers can be produced when various vehicles with different masses pass through the
bumps.

From the journal paper, DESIGN OF RACK AND PINION MECHANISM FOR POWER
GENERATION USING SPEED BREAKERS BY M. SAILAJA, M. RAJA ROY, S. PHANI
KUMAR (IJETT 2015), power was generated at speed breakers by using rack and pinion the
model has a smaller number of parts and the assembly would cost very less with all the components
being available regularly and no model specific parts are to be manufactured. The various
dimensions of the mechanism due to vehicular movement. The average load depends on the
vehicular frequency for each type of a vehicle which is called road data.

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From the journal paper, GENERATION OF ELECTRICITY WITH THE USE OF SPEED
BREAKERS BY PIYUSH BHAGDIKAR, SHUBHAM GUPTA, NAVNEET RANA (IJAET
MAY 2014), the electricity is generated by replacing the traditional speed breakers with some
simple mechanism. As vehicles pass over the speed breakers, they spin the rollers which are
connected to a generator which in turn generate electricity. This paper attempts to show how
energy can be tapped and used at a commonly used system, the road speed breakers. In this work
an attempt has been made to fabricate a ramp, which can utilize the kinetic energy of vehicles in
power generation. This type of ramp is best suited for the places where the speed breaker is a
necessity. The work also discusses the shortcomings of existing methods and the ways it is
countered by this method.

From the journal paper, DESIGN AND FABRICATION OF POWER GENERATION

SYSTEM USING SPEED BREAKER BY D. VENKATA RAO, K. PRASADA RAO, K
PRASADA RAO, S. CHIRANJEEVA RAO (IJECT 2014), attempts to show how energy can
be tapped and used at a commonly used system, the road speed breakers. In the present work, a
working model of the power generation unit is made. A similar model of the system has also been
modeled in Pro-E. Design of each component is carried out using standard procedures. The
components are fabricated and are finally assembled. Theoretical calculations of power and the
practical power obtained are compared in order to find the efficiency of the power generation unit.
The overall goal was to design the speed breaker System while keeping the engineering, producer
and customer models in check. The reason why this feature was used more than all of the other
features would not have as much effect on the complete system. By changing the size and desirable
price, weight and capacity can be realized. Future work would consist of a redesign of this model
to see exactly how much data we may be missing with the assumption that we made with low
price, weight and capacity.

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The energy crisis is a bottleneck in the supply of energy resources to an economy. The studies to
sort out the energy crisis led to the idea of generating power using speed breaker. First to make
use were South African people: their Electrical crisis has made them to implement this method to
light up small villages of the highway.

The idea of basic physics to convert the kinetic energy into electrical energy that goes waste when
the vehicle runs over the speed-Breaker was used. Since hen a lot has been done in this field. The
idea caught our working team and we have decided to develop such a project that will produce
more power and store it for use at night time as it proves to be a boon to the economy of the
country.

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CHAPTER 3

Problem Definition and Project Objective

3.1 Problem Definition

Some developing countries and newly-industrialized countries have several hours of daily power-
cut in almost all cities and villages because the increase in demand for electricity exceed the
increase in electric power generation people in these countries may use power-inverter
(rechargeable batteries) or diesel / petrol-run electric generator at their home during the power –
cut. The use of standby generator is common in industrial and IT hubs. This ultimately increase
the shortage of power.

3.2 Project Objective

• The challenge inspired us a lot and made us to think about for generating mechanism to save
the wasted power from automobiles to generate electricity
• To select an alternate source for generation of electricity for lightening the streets
• To design, develop and performance evaluation of the mechanical setup of the project work.
• To generate electricity at low price
• Ecofriendly system
• Using wasted kinetic and potential energy of vehicle at speed beaker.

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CHAPTER 4

4.0 Methodology
Power can be produced from conventional and nonconventional energy sources. In this paper we
show energy conversion from kinetic energy to rotational energy and rotational energy to electrical
energy respectively. This project explains the mechanism of electricity generation from speed
breakers. It is a simple but optimum process to generate energy from speed breaker arrangements.
There are a large number of vehicles running on the road. These vehicles are going over a number
of speed breakers present on the road. We want to replace these traditional speed breakers with
our proposed speed breaker. It is an Electro-Mechanical unit. This system utilizes both mechanical
technologies and electrical techniques for the power generation and its storage. The generation
will be proportional to the traffic density.

TRANMISSION
VEHICLE
PISTON / SPRING FREEWHEEL SHAFT AND
PRESSURE ON
ARRANGEMENT ARRANGEMENT BEARING
SPEED BREAKER
ARRANGEMENT

DISC/ MOTOR
INVERTER BATTREY GENERATOR
SETUP

SETUP OF TO OUTPUT
TRANSFORMER SOURCE

Figure.4.0.1. Representation of working using block diagram

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4.1 SPRING MECHANISM

A spring is an elastic object used to store mechanical energy. Springs are usually made out of
spring steel. There are a large number of spring designs; in everyday usage the term often refers
to coil springs.
Small springs can be wound from pre-hardened stock, while larger ones are made from annealed
steel and hardened after fabrication. When a coil spring is compressed or stretched slightly from
rest, the force it exerts is approximately proportional to its change in length (this approximation
breaks down for larger deflections). 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. An extension or compression spring has units of force divided by
distance, for example lab/in or N/m.
Torsion springs have units of torque divided by angle, such as NMS/rad or ft-lb/degree. The
inverse of spring rate is compliance, that is: if a spring has a rate of 10 N/mm, it has a compliance
of 0.1 mm/N. The stiffness (or rate) 5 of springs in parallel is additive, as is the compliance of
springs in series. Depending on the design and required operating environment, any material can
be used to construct a spring, so long as the material has the required combination of rigidity and
elasticity:

Figure 4.1.1 Spring Anatomy

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4.2 FREEWHEEL MECHANISM

The simplest freewheel device consists of two saw-toothed, spring-loaded discs pressing against
each other with the toothed sides together, somewhat like a ratchet. Rotating in one direction, the
saw teeth of the drive disc lock with the teeth of the driven disc, making it rotate at the same speed.
If the drive disc slows down or stops rotating, the teeth of the driven disc slip over the drive disc
teeth and continue rotating, producing a characteristic clicking sound proportionate to the speed
difference of the driven gear relative to that of the (slower) driving gear.

A more sophisticated and rugged design has spring-loaded steel rollers inside a driven cylinder.
Rotating in one direction, the rollers lock with the cylinder making it rotate in unison. Rotating
slower, or in the other direction, the steel rollers just slip inside the cylinder.

Most bicycle freewheels use an internally step-toothed drum with two or more spring-loaded,
hardened steel pawls to transmit the load. More pawls help spread the wear and give greater
reliability although, unless the device is made to tolerances not normally found in bicycle
components, simultaneous engagement of more than two pawls is rarely achieved.

Figure 4.1.2 Freewheel Mechanism

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4.3 CHAIN DRIVE MECHANISM

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.

Most often, the power is conveyed by a roller chain, known as the drive chain or transmission
chain, passing over a sprocket gear, with the teeth of the gear meshing with the holes in the links
of the chain. The gear is turned, and this pulls the chain putting mechanical force into the system.
Another type of drive chain is the Morse chain, invented by the Morse Chain Company of Ithaca,
New York, United States. This has inverted teeth.

Sometimes the power is output by simply rotating the chain, which can be used to lift or drag
objects. In other situations, a second gear is placed and the power is recovered by attaching shafts
or hubs to this gear. Though drive chains are often simple oval loops, they can also go around
corners by placing more than two gears along the chain; gears that do not put power into the system
or transmit it out are generally known as idler-wheels. By varying the diameter of the input and
output gears with respect to each other, the gear ratio can be altered. For example, when the bicycle
pedals' gear rotates once, it causes the gear that drives the wheels to rotate more than one
revolution. Duplex chains are another type of chain which are essentially two chains joined side
by side which allow for more power and torque to be transmitted.

Figure 4.1.3 Chain Drive Mechanism

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4.4 BEARING MECHANISM

A bearing is a machine element that constrains relative motion to only the desired motion, and
reduces friction between moving parts. The design of the bearing may, for example, provide for
free linear movement of the moving part or for free rotation around a fixed axis; or, it may prevent
a motion by controlling the vectors of normal forces that bear on the moving parts. Most bearings
facilitate the desired motion by minimizing friction. Bearings are classified broadly according to
the type of operation, the motions allowed, or to the directions of the loads (forces) applied to the
parts.
Rotary bearings hold rotating components such as shafts or axles within mechanical systems, and
transfer axial and radial loads from the source of the load to the structure supporting it. The
simplest form of bearing, the plain bearing, consists of a shaft rotating in a hole. Lubrication is
used to reduce friction. In the ball bearing and roller bearing, to reduce sliding friction, rolling
elements such as rollers or balls with a circular cross-section are located between the races or
journals of the bearing assembly. A wide variety of bearing designs exists to allow the demands
of the application to be correctly met for maximum efficiency, reliability, durability and
performance. The term "bearing" is derived from the verb "to bear"; a bearing being a machine
element that allows one part to bear (i.e., to support) another. The simplest bearings are bearing
surfaces, cut or formed into a part, with varying degrees of control over the form, size, roughness
and location of the surface. Other bearings are separate devices installed into a machine or machine
part. The most sophisticated bearings for the most demanding applications are very precise
devices; their manufacture requires some of the highest standards of current technology.

Figure 4.1.4 Pedestal Bearing Working

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4.5 GEAR MECHANISM

A gear is a rotating circular machine part having cut teeth or, in the case of a cogwheel or
gearwheel, inserted teeth (called cogs), which mesh with another (compatible) toothed part to
transmit (convert) torque and speed. The basic principle behind the operation of gears is analogous
to the basic principle of levers. A gear may also be known informally as a cog. Geared devices can
change the speed, torque, and direction of a power source. Gears of different sizes produce a
change in torque, creating a mechanical advantage, through their gear ratio, and thus may be
considered a simple machine.
The rotational speeds, and the torques, of two meshing gears differ in proportion to their
diameters. The teeth on the two meshing gears all have the same shape. Two or more meshing
gears, working in a sequence, are called a gear train or a transmission. The gears in a transmission
are analogous to the wheels in a crossed, belt pulley system. An advantage of gears is that the teeth
of a gear prevent slippage. In transmissions with multiple gear ratios—such as bicycles,
motorcycles, and cars—the term "gear" (e.g., "first gear") refers to a gear ratio rather than an actual
physical gear. The term describes similar devices, even when the gear ratio is continuous rather
than discrete, or when the device does not actually contain gears, as in a continuously variable
transmission.

Figure.4.1.5 Simple Gear Meshing

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CHAPTER 5

5.1 WORKING
Power generation using speed breaker (PGUSB) is a system design to capture waste and kinetic
energy from all vehicles. This device converts the kinetic energy of the vehicles into electric
energy. This is done by moving plate installed on the road, this plate captured very small movement
from the road surfaces and it transferred to chain and freewheel mechanism.
Here the reciprocating motion of the speed-breaker is converted into rotary motion using the chain
and freewheel arrangement. The axis of the chain is coupled to a freewheel arrangement. Here we
have two gears with same diameters connected to the freewheel using a connecting rod. The gear
wheel with the larger dimension is coupled to a smaller gear. Hence the rotation that has been
produced at the sprocket wheel is passed on to this gear wheel of larger dimension and then further
to the gear with smaller dimension.
The smaller gear is connected to the motor by a connecting rod. So as the freewheel rotates and,
the larger gear following the smaller gear. Hence, although the speed due to the rotary motion
achieved at the freewheel is less, as the power is transmitted to gears, finally the speed is multiplied
to a higher speed. This speed which is sufficient to rotate the rotor of a generator is fed into to the
rotor of a generator. The rotor which rotates within a static magnetic stator cuts the magnetic flux
surrounding it, thus producing the electric motive force (emf). This generated emf is then sent to
an inverter, where the generated emf is regulated. This regulated emf is now sent to the storage
battery where it is stored during the day time. This current is then utilized in the night time for
lighting purposes on the either side of the road to a considerable distance.

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5.2 MANUFACTURING PROCESSES

5.2.1 Arc Welding

Arc welding is a process used to join two similar or dissimilar metals. This method uses electrical
power to generate adequate heat to dissolve metals. On cooling, the metals get fused together.
The welding power supply is used create a circular segment between the cathode and the base
material to liquefy the metals at the point of welding. Different forms of gases cover the welding
region forming slag around it.
One of the most common types of arc welding is shielded metal arc welding (SMAW), which is
also known as manual metal arc welding (MMAW) or stick welding. An electric current is used to
strike an arc between the base material and a consumable electrode rod or stick. The electrode rod
is made of a material that is compatible with the base material being welded and is covered with a
flux that gives off vapours that serve as a shielding gas and provide a layer of slag, both of which
protect the weld area from atmospheric contamination. The electrode core itself acts as filler
material, making a separate filler unnecessary. The process is very versatile, requiring little
operator training and inexpensive equipment. However, weld times are rather slow, since the
consumable electrodes must be frequently replaced and because slag, the residue from the flux,
must be chipped away after welding. Furthermore, the process is generally limited to welding
ferrous materials, though specialty electrodes have made possible the welding of cast iron, nickel,
aluminium, copper and other metals. The versatility of the method makes it popular in a number
of applications including repair work and construction.

Figure.5.2.1 Basic Arc Welding Circuit Diagram

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5.2.2 Turning Operation

Turning is a machining process in which a cutting tool, typically a non-rotary tool bit, describes a
helix toolpath by moving more or less linearly while the workpiece rotates.
Usually the term "turning" is reserved for the generation of external surfaces by this cutting action,
whereas this same essential cutting action when applied to internal surfaces (holes, of one kind or
another) is called "boring". Thus, the phrase "turning and boring" categorizes the larger family of
processes known as lathing. The cutting of faces on the workpiece, whether with a turning or
boring tool, is called "facing", and may be lumped into either category as a subset.
Turning operation was used in our project for the manufacturing of bushes for the better fitment
of the gears and freewheel with the connecting rod that transfers the vertical motion into rotary
motion.
This operation was used to make bushes for the better fitment of components. Two bushes were
for the fitment of freewheel and connecting rod. And another two bushes were made for the gear
with lager inner diameter to perfectly fit the smaller diameter of the connecting rod.

Figure.5.2.2 Basic Turning Operation Diagram and Bushes

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5.2.3 Drilling Operation

Drilling is a cutting process that uses a drill bit to cut a hole of circular cross-section in solid
materials. The drill bit is usually a rotary cutting tool, often multi-point. The bit is pressed against
the work-piece and rotated at rates from hundreds to thousands of revolutions per minute. This
forces the cutting edge against the work-piece, cutting off chips (swarf) from the hole as it is
drilled.
In rock drilling, the hole is usually not made through a circular cutting motion, though the bit is
usually rotated. Instead, the hole is usually made by hammering a drill bit into the hole with quickly
repeated short movements. The hammering action can be performed from outside the hole (top-
hammer drill) or within the hole (down-the-hole drill, DTH). Drills used for horizontal drilling are
called drifter drills.
In rare cases, specially-shaped bits are used to cut holes of non-circular cross-section; a square
cross-section is possible.
This operation was used for drilling holes in the frame for the fitting of the pedestal bearing using
bolts. A vertical type drill machine was used for the purpose of drilling holes in the frame.

Figure.5.2.3 Basic Drilling Operation Representation and Vertical Drill Machine

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5.2.4 Grinding Operation

A grinding machine is machine tools which is used for removing of rough surface of a workpiece
with the help of rotating abrasive wheel that acts as a tool.
A grinding is metal cutting operation which is performed by means of a rotating abrasive wheel
that acts as a tool. These are mostly used to finish workpieces which must show a high surface
quality, accuracy of shape and dimension.
Mostly, it is finishing operation because it removes material in very small size of chips 0.25 – 0.5
mm. There accuracy in dimensions is in the order of 0.000025 mm. Grinding is also done to
machine materials which are too hard for other machining strategies that use cutting tools.
Hand held grinder was used for grinding the unwanted material left on the frame after any
operation is performed on the frame. Also, the grinder was used for grinding the connecting rod
end for the perfect fit in the bushes. The grinder was also used for cutting operation i.e., the frame
was cut using the hand grinder.

Figure.5.2.4 Diagram of A Hand Grinder

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CHAPTER 6

6.1 COMPONENTS DIMENSIONS

1. BOX METAL FRAME – GI metal box frame was used for the construction of a sturdy frame
to support the structure of the model.
DIMENSION: -
Cross section - 2 X 1 INCH
2. STEEL SHAFT – These rods were used for the transmission of rotation obtained by the
freewheel to the gears, and further to the motor arrangement.
DIMENSION: -
Length- 54.2 mm
Diameter- 2.9 mm
3. FREEWHEEL – It was used for the conversion of the up and down motion of the speed breaker
to rotary motion.
DIMENTION: -
Inner diameter- 35 mm
No of teeth – 18
4. GEAR – It was used for the transmission of rotational energy further to the motor with the help
of the rod.
DIMENSION (large): -
No of teeth- 56
Outer diameter- 116 mm
Inner diameter- 54 mm
DIMENSIONS (small): -
No of teeth- 24
Outer diameter- 54 mm
Inner diameter- 2.6 mm
5. BEARING – Pedestal bearings were used to provide support for the rod that transmitted the
power. Three bearings were used for individual rods. UCP 206 bearing was used for the project.
DIMENSIONS: -
Base- 42 X 156 mm
Inner diameter- 30 mm
6. SPRING – Spring was used for absorbing the sudden load applied by the moving vehicle and
also to sent the speed breaker back to its initial position. A motorcycle suspension spring was used
for the project.
DIMENSIONS: -
Thickness- 6 mm
Height- 221 mm
Diameter- 57 mm

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6.2. Output Power Calculations: -

Let us consider,
The mass of a vehicle moving over the speed breaker=150Kg (Approximately)
Height of speed brake=10 cm
Work done=Force x Distance
Here,
Force = Weight of the Body
=150 x 9.81
=1471.5N
Distance traveled by the body = Height of the speed brake
=10 cm
Output power = Work done/Sec
= (1471.5x 0.10)/60
=2.452Watts (For One pushing force)
Power developed for 1vehicle passing over the speed breaker arrangement
for one minute = 2.452watts
Power developed for 60 minutes (1 hr.) =147.12watts
Power developed for 24hours=3.531kilowatts

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6.3 COMPONENTS

6.3.1 PEDESTAL BEARING:

A pillow block bearing (or Plummer block) is a pedestal used to provide support for a rotating
shaft with the help of compatible bearings & various accessories. The assembly consists of a
mounting block which houses a bearing. The block is mounted to a foundation and a shaft is
inserted allowing the inner part of the bearing / shaft to rotate. The inside of the bearing is typically
0.001 inches (0.025 mm) larger than the shaft to ensure a tight fit. Set screws, locking collars, or
set collars are commonly used to secure the shaft. Housing material for a pillow block is typically
made of cast iron or cast steel.

A set screw is a screw that is used to secure an object, by pressure and/or friction, within or against
another object, such as fixing a pulley or gear to a shaft. A set screw is normally used without a
nut (which distinguishes it from a bolt), being screwed instead in a threaded hole drilled in only
one of the two objects to be secured. A set screw is often headless and threaded along its entire
length, so that it will sit entirely inside that hole; in which case it may be called a grub screw or
blind screw.

Figure.6.3.1Pedestal Bearing and Set Screw

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6.3.2 SPUR GEAR:

Spur gears or straight-cut gears are the simplest type of gear. They consist of a cylinder or disk
with teeth projecting radially. Viewing the gear at 90 degrees from the shaft length (side on) the
tooth faces are straight and aligned parallel to the axis of rotation. Looking down the length of the
shaft, a tooth's cross section is usually not triangular. Instead of being straight (as in a triangle) the
sides of the cross section have a curved form (usually involute and less commonly cycloidal) to
achieve a constant drive ratio. Spur gears gears mesh together correctly only if fitted to parallel
shafts. No axial thrust is created by the tooth loads. Spur gears are excellent at moderate speeds
but tend to be noisy at high speeds. Spur gear can be classified into two pressure angles, 20° being
the current industry standard and 14½° being the former (often found in older equipment). Spur
gear teeth are manufactured as either involute profile or cycloidal profile. When two gears are in
mesh it is possible that an involute portion of one will contact a non-involute portion of the other
gear. This phenomenon is known as "interference" and occurs when the number of teeth on the
smaller of the two meshing gears is less than a required minimum. Undercutting (cutting the tooth
narrower closer to its base) is sometimes used to avoid interference but is usually not suitable
because the decreased thickness leaves the tooth weaker at its base. In this situation Corrected
gears are used. In corrected gears the Cutter rack is shifted upwards or downwards. Spur gears can
be classified into two main categories: External and Internal.

Figure.6.3.2 Spur Gear

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6.3.3 SHAFT:

A shaft is a rotating machine element, usually circular in cross section, which is used to transmit
power from one part to another, or from a machine which produces power to a machine which
absorbs power. The material used for ordinary shafts is mild steel. When high strength is required,
an alloy steel such as nickel, nickel-chromium or chromium-vanadium steel is used. Shafts are
generally formed by hot rolling and finished to size by cold drawing or turning and grinding.

The following stresses are induced in the shafts:

• Shear stresses due to the transmission of torque (due to torsional load).
• Bending stresses (tensile or compressive) due to the forces acting upon the machine
element like gears and pulleys as well as the self-weight of the shaft.
• Stresses due to combined torsional and bending loads.
They are mainly classified into two types.
• Transmission shafts are used to transmit power between the source and the machine
absorbing power; e.g., counter shafts and line shafts.
• Machine shafts are the integral part of the machine itself; e.g., crankshaft.
• Axle shaft.
• Spindle shaft.

Figure6.3.3 Shaft

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6.3.4 FREEWHEEL

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.

The condition of a driven shaft spinning faster than its driveshaft exists in most bicycles when the
rider stops pedaling. In a fixed-gear bicycle, without a freewheel, the rear wheel drives the pedals
around.

An analogous condition exists in an automobile with a manual transmission going downhill, or

any situation where the driver takes their foot off the gas pedal, closing the throttle: the wheels
drive the engine, possibly at a higher RPM. In a two-stroke engine, this can be catastrophic—as
many two stroke engines depend on a fuel/oil mixture for lubrication, a shortage of fuel to the
engine starves oil from the cylinders, and the pistons can soon seize, causing extensive damage.
Saab used a freewheel system in their two-stroke models for this reason and maintained it in the
Saab 96 V4 and early Saab 99 for better fuel efficiency.

Figure6.3.4 Freewheel

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6.3.5 CHAIN:

A bicycle chain is a roller chain that transfers power from the pedals to the drive-wheel of a bicycle,
thus propelling it. Most bicycle chains are made from plain carbon or alloy steel, but some are
nickel-plated to prevent rust, or simply for aesthetics. A bicycle chain can be very energy efficient:
one study reported efficiencies as high as 98.6%. The study, performed in a clean laboratory
environment, found that efficiency was not greatly affected by the state of lubrication. A larger
sprocket will give a more efficient drive because it moves the point of pressure farther away from
the axle, placing less stress on the bearings, thus reducing friction in the inner wheel. Higher chain
tension was found to be more efficient: "This is actually not in the direction you'd expect, based
simply on friction".
On most upright bicycles, the chain loops through the right rear triangle made by the right chain
stay and seat tube. Thus, a chain must be separated, (or "broken”) unless the triangle can be split
(usually the seat stays). Chain can either be broken with a chain tool or at a master link. A master
link, also known as a connecting link, allows the chain to be inserted or removed with simpler
tools, or even no tools, for cleaning or replacement.
Some newer chain designs, such as Shimano and Campagnolo 10-speed chains, require a special
replacement pin to be used when installing or reinstalling a separated chain. An alternative to this
process is to install a master link, such as a SRAM Power Link or a Wippermann Connex.

Figure6.3.5 Chain and Chain Opening

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6.3.6 COIL SPRING:

A coil spring is a mechanical device which is typically used to store energy and subsequently
release it, to absorb shock, or to maintain a force between contacting surfaces. They are made of
an elastic material formed into the shape of a helix which returns to its natural length when
unloaded.

Under tension or compression, the material (wire) of a coil spring undergoes torsion. The spring
characteristics therefore depend on the shear modulus.

A coil spring may also be used as a torsion spring: in this case the spring as a whole is subjected
to torsion about its helical axis. The material of the spring is thereby subjected to a bending
moment, either reducing or increasing the helical radius. In this mode, it is the Young's Modulus
of the material that determines the spring characteristics. A spring is an elastic object used to store
mechanical energy. Springs are usually made out of spring steel. There are a large number of spring
designs; in everyday usage the term often refers to coil springs.

Figure6.3.6 Spring

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6.3.7 BOX FRAME:

A hollow structural section (HSS) is a type of metal profile with a hollow cross section. The term
is used predominantly in the United States, or other countries which follow US construction or
engineering terminology.

HSS members can be circular, square, or rectangular sections, although other shapes such as
elliptical are also available. HSS is only composed of structural steel per code.

HSS is sometimes mistakenly referenced as hollow structural steel. Rectangular and square HSS
are also commonly called tube steel or box section. Circular HSS are sometimes mistakenly called
steel pipe, although true steel pipe is actually dimensioned and classed differently from HSS. (HSS
dimensions are based on exterior dimensions of the profile; pipes are also manufactured to an
exterior tolerance, albeit to a different standard.) The corners of HSS are heavily rounded, having
a radius which is approximately twice the wall thickness. The wall thickness is uniform around the
section.

In the UK, or other countries which follow British construction or engineering terminology, the
term HSS is not used. Rather, the three basic shapes are referenced as CHS, SHS, and RHS, being
circular, square, and rectangular hollow sections. Typically, these designations will also relate to
metric sizes, thus the dimensions and tolerances differ slightly from HSS.

Figure6.3.7 Box Frame

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6.3.8 NUT AND BOLTS:

A bolt is a form of threaded fastener with an external male thread requiring a matching pre-formed
female thread such as a nut. Bolts are very closely related to screws.
A nut is a type of fastener with a threaded hole. Nuts are almost always used in conjunction with
a mating bolt to fasten multiple parts together. The two partners are kept together by a combination
of their threads' friction (with slight elastic deformation), a slight stretching of the bolt, and
compression of the parts to be held together.
In applications where vibration or rotation may work a nut loose, various locking mechanisms may
be employed: lock washers, jam nuts, eccentric double nuts, specialist adhesive thread-locking
fluid such as Loctite, safety pins (split pins) or lockwire in conjunction with castellated nuts, nylon
inserts (nyloc nut), or slightly oval-shaped threads.
The most common shape today is hexagonal, for similar reasons as the bolt head: six sides give a
good granularity of angles for a tool to approach from (good in tight spots), but more (and smaller)
corners would be vulnerable to being rounded off. It takes only one sixth of a rotation to obtain
the next side of the hexagon and grip is optimal. However, polygons with more than six sides do
not give the requisite grip and polygons with fewer than six sides take more time to be given a
complete rotation. Other specialized shapes exist for certain needs, such as wingnuts for finger
adjustment and captive nuts (e.g., cage nuts) for inaccessible areas.

Figure6.3.8 Nut and Bolt

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6.3.9 WASHERS:

A washer is a thin plate (typically disk-shaped, but sometimes square) with a hole (typically in the
middle) that is normally used to distribute the load of a threaded fastener, such as a bolt or nut.
Other uses are as a spacer, spring (Belleville washer, wave washer), wear pad, preload indicating
device, locking device, and to reduce vibration (rubber washer).

Washers are usually metal or plastic. High-quality bolted joints require hardened steel washers to
prevent the loss of pre-load due to brinelling after the torque is applied. Washers are also important
for preventing galvanic corrosion, particularly by insulating steel screws from aluminum surfaces.
They may also be used in rotating applications, as a bearing. A thrust washer is used when a rolling
element bearing is not needed either from a cost-performance perspective or due to space restraints.
Coatings can be used to reduce wear and friction, either by hardening the surface or by providing
a solid lubricant (i.e., a self-lubricating surface).

The origin of the word is unknown; the first recorded use of the word was in 1346, however, the
first time its definition was recorded was in 1611.

Rubber or fiber gaskets used in taps (or faucets, or valves) as seal against water leaks are sometimes
referred to colloquially as washers; but, while they may look similar, washers and gaskets are
usually designed for different functions and made differently.

Figure6.3.9 Washers

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6.3.10 DC MOTOR:
A DC motor is any of a class of rotary electrical motors that converts direct current (DC) electrical
energy into mechanical energy. The most common types rely on the forces produced by magnetic
fields. Nearly all types of DC motors have some internal mechanism, either electromechanical or
electronic, to periodically change the direction of current in part of the motor.
DC motors were the first form of motor widely used, as they could be powered from existing
direct-current lighting power distribution systems. A DC motor's speed can be controlled over a
wide range, using either a variable supply voltage or by changing the strength of current in its field
windings. Small DC motors are used in tools, toys, and appliances. The universal motor can
operate on direct current but is a lightweight brushed motor used for portable power tools and
appliances. Larger DC motors are currently used in propulsion of electric vehicles, elevator and
hoists, and in drives for steel rolling mills. The advent of power electronics has made replacement
of DC motors with AC motors possible in many applications.

Figure6.3.10 DC Motor

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6.3.11 WIRE AND LED BULB:

A wire is a flexible strand of metal, wires are commonly formed by drawing the metal through a
hole in a die or draw plate. Wire gauges come in various standard sizes, as expressed in terms of a
gauge number. Wires are used to bear mechanical loads, often in the form of wire rope. In
electricity and telecommunications signals, a "wire" can refer to an electrical cable, which can
contain a "solid core" of a single wire or separate strands in stranded or braided forms.

Usually cylindrical in geometry, wire can also be made in square, hexagonal, flattened rectangular,
or other cross-sections, either for decorative purposes, or for technical purposes such as high-
efficiency voice coils in loudspeakers. Edge-wound coil springs, such as the Slinky toy, are made
of special flattened wire.

A light-emitting diode (LED) is a semiconductor light source that emits light when current flows
through it. Electrons in the semiconductor recombine with electron holes, releasing energy in the
form of photons. The color of the light (corresponding to the energy of the photons) is determined
by the energy required for electrons to cross the band gap of the semiconductor. White light is
obtained by using multiple semiconductors or a layer of light-emitting phosphor on the
semiconductor device.

Figure 6.3.11 Wire and LED Bulb

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CHAPTER 7

7.1 RESULT:
Energy is important part to retain the industrial production rate and also the progress of any
Country. The conventional sources are reducing day by day and by the turn of century, we have to
depend upon the non-conventional sources of energy. (Non-conventional sources such as solar
energy, wind energy, biogas etc.)

We can also increase the growth of country by installing speed breaker in heavy traffic roads and
toll plaza. We can generate electricity almost continuously by using the weight of the vehicles to
produce mechanical power in the shafts by using the rack and pinion mechanism. As this method
does not require any external power source and the traffic never reduces, these speed breakers are
more reliable and have a greater life span.

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7.2 CONCLUSION:

"Electricity plays a very important role in our life”. Due to population explosion, the current power
generation has become insufficient to fulfill our requirements. In this project we discover
technology to generate electricity from speed breakers in which the system used is reliable and this
technique will help conserve our natural resources. In coming days, this 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. As the conventional sources are depleting very fast, it’s high time to think of
alternative resources. We got to save the power gained from the conventional sources for efficient
use. So, this idea not only provides alternative but also adds to the economy of the country.
Energy is generated and power produced by using the speed breaker as power generating unit and
installing a gear and rod mechanism. The energy we save during the day light can be used in the
night time for lighting street lights. Such a set-up can be placed independently across city lanes,
or along tolls on highways and other inter-city roads, or coupled with speed breakers anywhere in
the world. In countries like India and other countries where the road is filled with car or a place
where cars travel in larger frequency on a particular road this technology can be used for the
fulfilment of electricity.
In the upcoming and uprising EV culture this can be used to produce and store electricity on the
EV charging stations. In cities where there are many speed breakers this can be used to power the
street lights or signals. This can be used in rural areas to power up small things like water pump to
supply water to the villages. This can be a great alternative for solar which are expensive and also
can produce power at night which the solar panel cannot. We can even experience less power
generation by solar during rainy and winter season where there is less light falling on the panel,
which can be resolved by this alternative.

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REFERENCE:
1. Using speed bump for power generation experimental study by Mohamad ramadana, Mahmoud
Khaleda b, Hicham El Hagea (science direct-applied energy icte 2015)

2. Design of rack and pinion mechanism for power generation using speed breakers by m. Sailaja,
m. raja Roy, s. panic Kumar (ijett 2015)

3. Generation of electricity with the use of speed breakers by Piyush Bhagdikar, Shubham Gupta,
Navneet Rana (ijaet may 2014)

4. Design and fabrication of power generation system using speed breaker by d. Venkata Rao,

K. Prasad Rao, K Prasad Rao, S. Chiranjeevi Rao (iject 2014)

5. Joardder M.U.H, Kabir M, Barua R, Hoque M. Loss to assets: production of power from speed
breaker. Int. Conf. Mech.

6. Partodezfoli M, Rezaey A, Baniasad Z, Rezaey H. A Novel Speed-Breaker for Electrical Energy

Generation Suitable for Elimination of Remote Parts of Power Systems where is Near to Roads. J.
Bas. Appl. Scient. Resear. 2012; 2:6285-6292.

7. Fatima N, Mustafa J. Production of electricity by the method of road power generation. Int. J.
Adv. Electrical Electronics2012; 1:9-14.

8. Panwar N.L, Kaushik S.C, Kothari S. Role of renewable energy sources in environmental
protection: A review. Renew Sustainable Energy Rev 2011; 15:1753-1766.

9. Solangi K.H, Islam M.R, Saidur R, Rahim N.A, Fayaz H. A review on global solar energy
policy. Renew Sustainable Energy Rev2011; 15:2149-2163.

10. Joselin Herbert G.M, Iniyan S, Sreevalsan E, Rajapandian S. A review of wind energy
technologies. Renewable and Sustainable Energy Reviews 2007; 11:1117-1145.

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