DESIGN AND FABRICATION OF

ROAD POWER GENERATOR

A PROJECT REPORT

Submitted by

JOHN ARUL RAJ.A

JESU POLISTON RAJ.S
SIVABALAN.A
TYCHICUS.S
In partial fulfillment for the award of the degree

Of

BACHELOR OF ENGINEERING
In

MECHANICAL ENGINEERING

ST.MOTHER THERESA ENGINEERING COLLEGE, TUTICORIN

– 628 102

ANNA UNIVERSITY: CHENNAI : 600 025

APRIL 2021
 ANNA UNIVERSITY : CHENNAI : 600 025

BONAFIDE CERTIFICATE
Certified that this project report “DESIGN AND FABRICATION OF ROAD
POWER GENERATOR” is the work of “JOHNARUL RAJ.A, JESU
POLISTON RAJ.S, SIVA BALAN.A, TYCHICUS.S” who carried out the
project work under my supervision.

SIGNATURE SIGNATURE

Mr.S.MUTHU KRISHNAN Mr.R.SAMUEL SANJAY

RAJA

M.E., M.E.,

HEAD OF THE DEPARTMENT, SUPERVISOR,

ASSISTANT PROFESSOR, ASSISTANT

PROFESSOR,

DEPARTMENT OF MECHANICAL DEPARTMENT OF

MECHANICAL

ENGINEERING, ENGINEERING,

ST.MOTHER THERESA ST.MOTHER THERESA

ENGINEERING COLLEGE, ENGINEERING

COLLEGE,

TUTICORIN – 628 108. TUTICORIN – 628 108.

Submitted for the university examination held on 09-08-2021

Internal Examiner External Examiner

AKNOWLEDGEMENT
First of all, I would like to thank God, the Almighty, for having made everything
possible by giving us strength and courage to complete our mini project with grand
success. At very outset, we express our sincere thanks to our beloved parents,
who have blessed us with healthy constitution and have bestowed upon us the
required skill to pursue the Hi-Tech courses.

We pour our profound gratitude to our respected Ass.Prof.S.MUTHU

KRISHNAN. M.E., Head of the Department of Mechanical Engineering for
providing amble facilities made available to undergo our mini project a great
success.

We thank our project Guide Ass.Prof.V.PRABHU M.E.,

Department of Mechanical Engineering for his excellent guidance patiently
throughout our project work.

We would like to thank our project supervisor Ass.Prof.R.SAMUEL

SANJAY RAJA M.E., Department of Mechanical Engineering for his continuous
support, encouragement and guidance.

We also bound to thank our Faculty members and Laboratory

Technicians of the Department of Mechanical Engineering, whose support and
cooperation contributed to complete this project work.
 TABLE OF CONTENT
CHAPTE TITLE PAGE NO.
R NO.
ACKNOLEDGEMENT Vi

ABSTRACT V
LIST OF FIGURES Viii
LIST OF TABLES iX

1 INTRODUCTION 1

2 LITERATURE REVIEW 2

3 METHADOLOGY
3.1 Bearing 2

3.1.1 Ball Bearing 3

3.1.2 Roller Bearing 3

3.2 NOMENCULTURE 5
3.3 IMPORTANT NOTES 7
3.4 INTERFERENCE 7
3.5 GEAR STANDARDS 7

3.6 DC GENERATORS 8

3.6.1 Armature Winding 11

 3.6.2 Lap Winding 11

3.7 INVERTERS 11

4 DESIGN CALCULATION 12

4.1 Experimental Investigation 13

4.2 Material Selection 14

4.4 Project Layout 15

4.6 Material Selection 16

4.5 Advantages 16
4.6 Cost Estimation 17

5 CONCLUSION 18
5.1 Scope of Paper 18

REFERENCE 19
 LIST OF TABLES

TABLE NO. TITLE PAGE NO.

1 Voltage generated Vs Speed of 15

vehicle

2 Material Selection 15

3 Cost of Estimation 15
 LIST OF FIGURES
FIGURE TITLE PAGE NO.
NO.
3.1 Ball Bearing 5

3.2 Roller Bearing 5

3.3 Gear Nomenclature 5

3.4 Working Clearance 6

3.5 Gear Mounting 8

3.6 DC Generator 10

3.7 Right Hand Rule 11

3.8 Diode Bridge Rectifier 13

4.1 Layout of Project 18

CHAPTER –I
 INTRODUCTION

The automotive industry in India is one of the largest in the world and one of the
fastest growing globally . India’s passenger car and commercial vehicle
manufacturing industry is the seventh largest in the world , with an annual
production of more than 3.7 million units in 2010 . We every day mesh up with
these vehicles give us headache . But this mesh up could be answer of new type
power generation . Road power Generator (RPG) is one of the most recent power
generating concepts . This device is engineered as a practical and useful
alternative energy technology for generating clean electricity from the millions of
vehicles on our roadways . Once fully optimized and installed , engineers
anticipate that devices may be used to augment or replace conventional electrical
supplies for powering roadways signs , street and building lights , storage systems
for back-up and emergency power, and other electronic appliances, and even
devices used in homes and businesses. Due to the advent and development in
the field of renewable energy sources, the dependence on fossil fuels and
conventional energy sources has been decreased drastically. This has lead to
higher penetration and use of Distributed Resources. The rapid increase in the
demand for electricity and the recent change in the environmental conditions
such as global warming led to a need for a new source of energy. As we are
aware of the fact that the number of vehicles are increasing day by day. Every
time a vehicle passes over speed Breaker, large amount of energy is wasted
through friction. There is great possibility of generating power by tapping this
energy. By just placing a unit like the “Power Generation Unit from speed
Breakers” or “Road Power Generator” ,a significant amount of energy can be
tapped . This generated electricity can be used for different purpose such as
,lightning of street lights , battery charging and signal lights on road etc. The
proposed design offers pollution free power generation, would cause no
obstruction in traffic, leading to low budget electricity production. It would
occupy floor area and it maintenance would be easy. The power generated by this
technique can be used in street lights, road signals , lightning of the bus stops,
lightning of the check posts on the highways ,etc.

CHAPTER 2
 LITERATURE REVIEW

S.N Journal name

o and data Title Year of Interference
Publication

1 International Production if Year:2010/ The method of drying

journal of electricity by the Volume : 2 and temperature
advances in method of Road /Issue :1/ reduces the moisture
electrical and Power Generator Page No:9-14 content and drying
electrical time.
engineering

2 International Introducing speed Year:2013 The heat energy

journal of breakers as a power /Issue : 1/ required from AC
research and generation unit for Page No:978 waste heat saves 4
science minor needs LPG cylinder per year.

3 International Design of Road Year:2008/ Electrical conductivity

journal of Power Generator Volume : 38/ of speed reduces with
engineering and (RPG)an Alternative Page No:1236- respect to increase in
technology energy source for 1244 temperature.
sustainability

CHAPTER 3
 METHADOLOGY

 Approach in this section , it was tried to understand the working principle

of the RPG designed system in practical implementation and its advantages.
 Materials in this section , there are several basic materials required to
generate electricity by the road speed breakers The main where used as
i.e,Bicycle , Rim ,Pulley, mild steel frame ,1293D , inverter , spurgear , Rack
and Pinion gear , ball bearing .
 Working principle Road Power Generator (RPG) is a system design to
capture waste and kinetic energy from all vehicles . This device converts the
kinetic energy of the vehicles into electrical energy . This is done by moving
plate installed on the road , this plate capture small movement from the
road surface and it transfers to a keyway flywheel system From hundreds of
wheel lies a single flywheel having used to drive machinery . The RPG
flywheel system has been developed to achieve large amount of moment of
inertia in relatively small space . The captured energy is converted to
electricity Which is fed into power grid . with the following block diagram
we can easily understand the overall working of the automatic street light.
The sensor LDR has the property to change its resistance according to the
intensity of the light.As the intensity of light falling at LDR increases , its
resistance get decreased and so on . Hence the total amount of light
remains constant.
3.1.BEARING
A bearing is machine elements Which supports another moving
machine elements . The moving machine is known as journal. Bearing
permits a relative motion between the content surfaces of the members ,
While carrying the load . A certain amount of power is wasted in
overcoming frictional resistance , In order to reduce frictional resistance
and wear and to carry away the heat generated , lubricant may be
provided. The lubricant used in usually a mineral oil refined from
petroleum. The bearing block is used to hold the bearings it is made up of
cast iron. All the bearings are fitted on the machine frame. A bearing is
machine element which supports another moving machine element.
 A bearing is a device to permit constrained relative motion between two
parts , i.e., rotation or linear movement , Bearing is used to reduce the
friction and increase the frictionless rotation of the shaft. There is a rolling
contact bearing is used. A rolling contact bearing consist of four parts –
Inner Race
Outer Race
1. A rolling element (ball , roller , needle etc,)
2. Cage

Despending upon the type of rolling contact , the bearing m111ay be classified as
follows-

3.1.1 Ball Bearing

A ball bearing is the type in which the balls are used as a rolling
element. The balls are placed inside the gap between the inner and outer race.
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. One of the races is held fixed. As one of
the races bearing rotates it causes the balls to rotate as well. Because the balls
are rolling they have a much lower coefficient of friction than it two flat surfaces
were rotating on each other. Ball bearing tends to have lower load capacity for
their size than other kind of rolling element bearing due to the smaller contact
area between the balls and races. However , they can tolerate some misalignment
of the inner and outer races. Compared to other bearing types , the ball bearing is
the least expensive , primarily because of the low amount of producing the balls
used in the bearing.

3.1.2 Roller Bearing

A roller bearing use cylinders of slightly greater length than diameter

in the gap between outer and inner races. Roller bearing have higher radial load
capacity than ball bearing , but a low axial capacity and higher friction under axial
loads. If the inner and outer races are misaligned , the bearing capacity drops
quickly compared to either a ball bearing or a spherical roller bearing.

3.2NOMENCATURE

Since spur gear are the simple type , it will be used for illustration and to
define the primary parameters of gears and their relations. The figure illustrates
the terminology of spur gears.

 Pitch circle the theoretical circle upon which all gear calculation are based
and Its diameter is called the “pitch diameter”.
 Pitch circles of mating gears are tangent to each other.
 Addendum and Dedendum circles: the circles defining the top and bottom
faces of theteeth.
 Addendum “a”: the radial distance from the pitch circle to the top surface
of the teeth
 Dedendum “b”: the radial distance from the pitch circle to the bottom
surface of the teeth
 Circle: The circle tangent mating gear. The radial distance between the add

circle is called the “working depth”.

 Clearance ”C”: The distance between the tooth top surface and the bottom
surface of a mating gear.
 Circular pitch “p”: The distance measured on the pitch circle from a point
on one tooth to the corresponding point on an adjacent tooth. The circular
pitch is equal to the sum of “tooth thickness” and “width of space “. The
width of space is slightly larger than the tooth thickness such that mating
teeth can engage easily without obstruction.
 Module “m”: is the ratio of pitch diameter to the number of teeth of a gear

3.3 Important notes

 The module determines the size of gear teeth.

 In order for gears to be able to mesh ,they must have the same
module.
 The pitch diameter of a gear is determined based on its module and
the number of teeth.
3.4 Interference

The contact of portion of teeth profiles that are not involved is called
interference.

 Interference happens in gear pairs because the dedendum circle is smaller

than the base circle and thus the involute portion of teeth profile is small.
 Thus ,,to reduce interference larger pressure angles 20◦or25◦ are
commonly used.

3.5 Gear standards

Usually , gears are designed on standards established by ISO or ANSI

 The standards specify the different parameters used to define the

geometry of gears and the relationships between these parameters.
 The standards were developed to attain inter changebility of gears having
the same pressure angle and module regardless of the number of teeth.
 The table gives the preferred values of Module and Diametral Pitch
according to the ISO and ANSI standards.
 Gear manufactures make a large variety of standards sized gears and such
gears can usually be available as off the shelf components.
 When a standard gear is chosen , the gear is usually not shown in full detail
in technical drawings , as shown in the mating element
 The Mounting Distance is the distance from the back surface of the gear to
the center line of the mating element , as seen in the Figure above.
 A straight bevel gear is designed by its , module , number of teeth , number
of teeth of the pinion , pressure angle , and face width.
 Example : Straight Bevel Gear 4M 25GT 15PT 20PA 18PA 18FW

3.6 DC GENERATOR

Generator principle: An electrical generator is a machine which converts

mechanical energy into electrical energy. Induced e.m.f is produced in it according
to Faraday’s Law of electromagnet induction. This e.m.f cause a current flow if
the conductor circuit is closed. Hence , two basic essential part of an electrical
generator are : a)Magnetic Field. B)Conductor or conductors which can move as
to cut the flux. Generators are drive by a source of mechanical power, which is
usually called the prime mover of the generation.

Simple loop generator is shown a single turn rectangular copper coil rotating
about its own axis in a magnetic field provided by either permanent magnets or
electromagnets. The two ends of the coil are joined to two slip-rings which are
insulate from each other and from the central shaft. Two collecting brushes press
against the slip-rings. The rotating coil may be called and the magnets as. One
way to generate an AC Voltage is to reduce a coil of wire at constant angular
velocity in a fixed magnetic field. The magnetic of a resulting voltage is
proportional to the rate at which flux lines are cut , and its polarity is dependent
on the direction of the direction the coil sides moves through the field .

The direction of an induced e.m.f can be predetermined by using Flemings right-

hand rule first-finger –field Thumb-Motion Second finger – e.m.f . Since the rate
of cutting flux varies with time, the resulting voltage will also vary with time. For
example in (a), Since the coil sides are moving parallel to the field , no flux lines
are being cut and the induced voltage at this instant is zero. As the coil from the
OP◦P position, Coil sides AAPP and BBPP cut across flux lines , hence , voltage
builds , reaching a peak when flux is cut the maximum rate in the 90P◦P position
as in (b). Note the polarity of the voltage and the direction of current. As the coil
rotates further , voltage decreases , reaching zero at the 180P◦ position when the
coil slides again move parallel to the field as in (c). At this point, the coil has gone
through a half-revolution. During the second half-revolution , hence , the polarity
of the induced voltage reverses. As indicated in (d), voltage reaches a peak at the
270P◦P point , and, since the polarity of the voltage has changed, so has the
direction of current When the coil reaches the 380P◦P position, voltage is again
zero and the cycle starts over one cycle of the resulting waveform. Since the coil
rotates continuously , the voltage produced will be a respective, periodic
waveform as you saw E.m.f generated in one side of loop= ϕ sin – Biv , and total
e.m.f generated in loop= ϕ sin2 x BIv (volts), where (B): flux density in (1): length
in; the conductor velocity, is measured in meters per second.
3.6.1 Armature winding

Armature winding can be divided into two groups, depending on how

the wires are joined to the commutator. These are called lap winding and wave
winding . These winding will be examined individually below , and their advantage
and disadvantage will be discussed.

3.6.2 Lap Winding

The simplest type of winding construction used in modern DC machines is the

simple lap winding. A simplex lap winding is a rotor winding consisting one or
more turns of wire the two end of each coil coming out at adjacent commutator
segments. The number of current paths in a machine is:

m = pa lap winding,

Where: a: number of current path in the rotor.

m:complex of the windings (1,2,3,etc…..)

p:number of poles on the machines.

Lap wound generators produce high current, low voltage output.

3.7 INVERTERS

An inverter is a motor control that adjusts the speed of an AC induction

motor. It does this by varying the frequency of the AC power to the motor. An
inverter also adjusts the voltage to the motor.

This process taken place by using some intricate electronic circuitry that controls
six separate power devices. They switching process is also called inverting DC bus
voltage and current into the AC waveforms that are discussion, the term
“inverter” will be used in place of adjustable speed drive.

How does an inverter work?

Most inverters are of the variable voltage, variables frequency design. They
consist of a converter section, a bus capacitor section and an inverter section. The
converter section uses semiconductor devices to rectify the incoming fixed
voltage, fixed frequency 3-phrase AC power to d voltage which is stored in the bus
capacitor bank. There it becomes a steady source of current for the power devices
which are located in what is known as the inverting section. The inverting section
absorbs power from the DC bus cap bank , inverts it back to simulated 3-phrase
AC sine waves of varying voltage and varying frequency that are typically used to
vary the speed of a 3-phrase induction motor.

CHAPTER 4

DESIGN CALCULATION

Let us consider,

 The mass of a vehicle moving over the speed breaker = 300Kg

(Approximately)

 Height of speed brake = 10cm

 Work done= Force x Distance

Here,

 Force = Weight of the body = 300 Kg x 9.81 = 2943 N

 Distance travelled by the body = Height of the speed brake = 10cm
 Output power = Work done/Sec = (2943 x 0.10)60=4.905 Watts (For
One pushing force)
  Power developed for 1 vehicle passing over the speed breaker
arrangement for one minute = 4.905 watts
 Power developed for 60 minutes (1hr) = 294.3 watts
 Power developed for 24 hours = 7063.2 W

This power is sufficient to burn four street lights in the roads in the night
time.

4.1 Experimental Investigation

The experimental investigation is performed by placing the speed breaker

arrangement in a pit. Vehicles move over the speed breaker arrangement and
the voltage generated is measurement by a multimeter and the various
readings are plotted in a graph. The graphs are drawn for various parameters
as shown below

1. Voltage generated (Vs) speed of vehicle

2. Voltage generated (Vs) Load
Total load = 360 Kg (Vehicle load + man weight)
Table 1
Summary of Voltage generated versus speed of vehicles

SI No. Speed of vehicles Voltage generated

(Km/hr) (volts)
1. 10 5.93
2. 20 6.32
3. 30 7.05
4. 40 8.65
5. 50 9.04

4.3 MATERIAL SELECTION:

Table 2

COMPONENT MATERIAL USED QUANTITY

Rack and pinion Mild steel 1
 Spur gear Mild steel 1
Shaft Mild steel 1
Ball bearing Stainless steel 1

4.4 LAYOUT OF THR PROJECT:

4.6 Advantages:
 Pollution free power generation
 Low installation and maintenance cost
  No manual work is required during the process
 No fuel transportation
 Less floor area
 No Obstruction to traffic
 Suitable at parking of multiplexes malls, signals ,etc.,
 Energy available all year

4.7 COST ESTIMATION

Table 3

SI.No. MATERIA QUANTITY COST/UNIT TOTAL COST IN

 L NAME RUPEES
1 Rack and 1 850 850
pinion
2 Ball 3 250*3 750
bearing
3 Generator 1 340 340

4 Inverter 1 450 450

5 Battery 1 250 250
6 Spur gear 1 150 150
7 Shaft 2 2*64 128
8 L shaped 4*400mm 26*25 650
angle bar 4*250mm
9 Others 1000 1000
Total cost 5068

CHAPTER 5

CONCLUSION
Road Power Generation is new type of uncoventional source of energy. This is a
type of vibration harvesting. This used waste energy of vehicles and converts
kinetic energy to electric energy. RPG possible answer for battery charging with
green power and power coming from electric vehicles earned wasted kinetic
energy. The higher frequency of passing vehicles provides higher capacity of
electrically generated by roadd power generation.

5.1 SCOPE OF THE PAPER

The utilization of energy is an indication of the growth of a nation. For example,

the per captia energyconsumption in USA ia 9000K Wh. One might conclude that
to be materially rich and prosperous, a human being needs to consume more and
more energy. A survey on the energy consumption in India had published a
pathetic report that 85,000 villages in India do not still have electricity. Supply of
power in most part of the country is poor. Hence more research and development
and commercialization of technologies are needed in this field. India, unlike the
top developed countries has very poor roads. Talking about a particular road itself
includes a number of speed breakers. By just placing a unit like the “Power
Generation Unit from Speed Breakers”, so much of energy can be tapped. This
energy can be used for the lights on the either sides of the roads and thus much
power that is consumed by these lights can be utilized to send power to these
villages.

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