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Diploma Mechanical Final Year Project
Diploma Mechanical Final Year Project
Project Report on
Project by
Project Guide
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Rajiv Gandhi College of Engineering
Department of Mechanical Engineering
CERTIFICATE
This is to certify that
Mr. Kolhe Prashant Dilip (598020)
Mr. Kharat Akash Ramdas (598017)
Mr. Pathare Arjun Madhukar (598023)
Mr. Dukare Dhanesh Shivaji (598002)
has successfully completed the Project on entitled ―“Electricity Generation for
Suspension System” under my supervision, in the partial fulfillment of Diploma in
Mechanical Engineering. It is submitted in the partial fulfillment of the prescribed
syllabus of MSBTE, Mumbai.
Date:
Place:
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PROJECT APPROVAL SHEET
MSBTE, MUMBAI
Project Entitled
“Electricity Generation for Suspention System”
Submitted By
Date:
Place:
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ACKNOWLEDGMENT
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INDEX
Sr. No. Topics Page. No.
1 Introduction 6
3 Project Model 10
4 Transmission System 13
5 Electrical System 15
6 Alternator 17
7 Principal of Operation 18
10 Process Sheet 26
11 Cost Estimation 30
12 Activity Chart 32
14 Future scope 34
15 Conclusion 35
15 Photo Gallery 36
16 Bibliography 40
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1. INTRODUCTION
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2 NON-CONVENTIONAL ENERGY SOURCES
a) Solar Energy (Photovoltaic)
Energy from the sun can be directly converted to electricity using solar cells,
also known as photovoltaic or PVs. Today's solar electric systems have 20 to 25
year warranties, are pollution free and can be used to offset your utility power or
as stand-alone power for remote applications. The down side to this technology is
that it costs three to five times more than utility power.
c) Barriers
Supply uncertainty and transportation costs have historically been barriers to
greater use of forest and agricultural residue for energy production. New
technologies such as gasification combined-cycle power generation, fuel cells
using biogas as a hydrogen source and cellulose-to-ethanol facilities that could co
generate electricity have yet to be demonstrated on a commercial scale. The
perceived risk of these newer technologies is a significant barrier, at least in the
short term.
d) Renewable Energy
Renewable energy is energy from any source that can be maintained in a
constant supply over time. In contrast, the supply of fossil energy sources such as
thus we selected nonconventional energy means the “Energy in motion when it is
suddenly applied with a sort of obstacle, then according to Newton’s law for every
action there is an equal and opposite reaction. Utilization of this reaction is the
basic reason behind the selection of this project work.
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Oil, natural gas or coal is limited. There are five principal renewable sources
of energy: flowing water, biomass, wind, the sun and heat from within the earth.
Heat, electricity and vehicle fuel are the main forms of energy that people use
every day. All renewable energy sources be used to produce electricity. Solar
energy and geothermal energy can supply both electricity and heat. Biomass is
unique because it can supply all three forms of useful energy. In 2001, renewable
energy supplied about 6 percent of all energy consumed in the United States.
Hydropower and biomass energy accounted for 92 percent of all renewable energy
consumed. About 11 percent of all electricity used in the country was generated
from renewable sources.
e) Sun
The sun is a constant natural source of heat and light. Sunlight can be
converted to electricity. Solar energy is energy that comes directly from the sun.
f) Biomass
"Biomass" describes, in one word, all plants, trees and organic matter on the
earth. Biomass is a source of renewable energy because the natural process of
photosynthesis constantly produces new organic matter in the growth of trees and
plants. Photosynthesis stores the sun's energy in organic matter. That energy is
released when biomass is used to make heat, electricity or liquid fuels.
g) Wind
The wind blows because of natural conditions of climate and geography.
Historically, wind power was used to supply mechanical energy, for example to
pump water, grind grain or sail a boat. Today, wind power is primarily a source of
electricity.
h) Water
Like the wind, flowing water is a product of the earth's climate and
geography. Snowmelt and runoff from precipitation at higher elevations flow
toward sea level in streams and rivers. In an earlier era, water wheels used the
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power of flowing water to turn grinding stones and to run mechanical equipment.
Modern hydro-turbines use water power to generate electricity.
i) Earth
Heat from deep within the earth is called "geothermal energy." In some
locations, geothermal energy is close enough to the surface that, by drilling a well
to reach the heat source, the energy can be extracted and used for heating
buildings and other purposes. Where the temperatures are hot enough, geothermal
energy can be used to generate electricity.
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3 PROJECT MODEL
3.1 Components
1. Frame Angle size 4.2x1.5x4 ft
2. Dynamo
3. Hair Axle
4. Chain Sprocket Wheel
5. Sprocket Freewheel
6. L.E.D
7. Chain
8. Spring
9. Chain Rack
10. Ball Bearing
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Fig. 2: Auto cad Model
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3.2 Construction
Frame forms the main part on which the one side is mounted. The plate is,
attached to the chain rack at one end and to the spring at another end, on which
force is applied. The freewheel is mounted on first sproket which is mesh with the
chain chain rack . The chain chain rack is provided with spring at bottom to obtain
its initial position.
On the freewheel shaft the sproket is mounted having 43 teeth.The half axel
is supported with angle. A chain mechanisum is provided to increase the speed. At
end half axle of chain mechaisum, the sprocket is mounted. It is connected to the
small sprocket on dynamo with the help of chain transmission. L.E.D. is
connected to dynamo.
3.3 Working
When force is applied on the plate the chain chain rack reciprocates. This
reciprocating motion of chain chain rack is converted into rotary motion by the
freewheel which is mesh with chain rack. This rotary motion is transmitted to big
sproket with the help of chain mechanisum. This chain mechanisum is used to
increase speed by 2.76 times. The rotary motion of big sproket is transmitted to
dynamo shaft small sproket by chain drive. The rpm of the dynamo is 80 to 100
rpm which is sufficient to generate electricity from dynamo. As dynamo rotates
electricity is generated and L.E.D. glows.
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4 TRANSMISSION SYSTEM
4.1 Introduction
The mechanical power produced by prime over I used to drive various
machines in the workshop and factories. A transmission system is the mechanism,
which deals with transmission of the power and motion from prime mover to shaft
or from one shaft to the other. The machine tool drive is an aggregate of
mechanism that transmits motion from an external source. To the operative
elements of the machine tool. The external source of energy is generally a
dynamo, which has a rotary motion at its output shaft.
The rotary motion of the motor is transmitted to the operative element to
provide an operative working or auxiliary motion. When the required motion is
rotary; the transmission takes place through mechanisms that transfer Rotary
motion from one shaft to another. Transmission of the motion from the external
source to the operative element can take place through Mechanical elements such
as belts, Gears, chains etc.
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transmitted is not positive when positive action is required. Gears and chain must
be used.
Efficiency of power transmission in belt and rope drives is less. The power
may be transmitted from one shaft another by means of mating gears with high
transmission Efficiency and a gear drive is also provide when the between driver
and follower is very small.
Chains are used for high transmission number. They are mostly used when
distance between center is short but the center distance is as much as 8m. They are
now generally used for transmission of power in cycle, motor vehicle, and
agriculture machinery in workshops.
It is general requirement for any machines that they should provision for
regulating speed of travel.
The regulation may be available in discrete steps or it may be steeples i.e.
continuous. The format are known as stepped drives Ex. Lathe machine, milling
machine, printing machine etc.
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5 ELECTRICAL SYSTEM
5.1 Dynamo
5.2 Description
The dynamo uses rotating coils of wire and magnetic fields to convert
mechanical rotation into a pulsing direct electric current through Faraday's law of
induction. A dynamo machine consists of a stationary structure, called the stator,
which provides a constant magnetic field, and a set of rotating windings called the
armature which turn within that field. The motion of the wire within the magnetic
field causes the field to push on the electrons in the metal, creating an electric
current in the wire. On small machines the constant magnetic field may be
provided by one or more permanent magnets; larger machines have the constant
magnetic field provided by one or more electromagnets, which are usually called
field coils.
The commentator was needed to produce direct current. When a loop of wire
rotates in a magnetic field, the potential induced in it reverses with each half turn,
generating an alternating current. However, in the early days of electric
experimentation, alternating current generally had no known use. The few uses for
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electricity, such as electroplating, used direct current provided by messy liquid
batteries. Dynamos were invented as a replacement for batteries. The
commentator is essentially a rotary switch. It consists of a set of contacts mounted
on the machine's shaft, combined with graphite-block stationary contacts, called
"brushes", because the earliest such fixed contacts were metal brushes. The
commentator reverses the connection of the windings to the external circuit when
the potential reverses, so instead of alternating current, a pulsing direct current is
produced.
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6 ALTERNATOR
6.1 History
Alternating current generating systems were known in simple forms from the
discovery of the magnetic induction of electric current. The early machines were
developed by pioneers such as Michael Faraday and HippolytePixii.
Faraday developed the "rotating rectangle", whose operation was heteropolar -
each active conductor passed successively through regions where the magnetic
field was in opposite directions.[1] The first public demonstration of a more robust
"alternator system" took place in 1886.[2] Large two-phase alternating current
generators were built by a British electrician, J.E.H. Gordon, in 1882. Lord Kelvin
and Sebastian Ferranti also developed early alternators, producing frequencies
between 100 and 300 Hz. In 1891, Nikola Tesla patented a practical "high-
frequency" alternator (which operated around 15 kHz).[3] After 1891, polyphase
alternators were introduced to supply currents of multiple differing phases.[4] Later
alternators were designed for varying alternating-current frequencies between
sixteen and about one hundred hertz, for use with arc lighting, incandescent
lighting and electric motors.[5]
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7 PRINCIPLE OF OPERATION
Fig. 3:
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voltage varies directly with the speed of the generator. Brushless AC generators
are usually larger machines than those used in automotive applications. An
automatic voltage control device controls the field current to keep output voltage
constant. If the output voltage from the stationary armature coils drops due to an
increase in demand, more current is fed into the rotating field coils through the
voltage regulator (VR). This increases the magnetic field around the field coils
which induces a greater voltage in the armature coils. Thus, the output voltage is
brought back up to its original value.
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8 DESIGN AND FABRICATION
8.1 Design of Transmission of System
1 = 36
x 60
x = 1.66
Small gear rotation = 1.66 rotation
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1 = 30
x 150
30 x = 150 x 1
x = 5 rpm
RPM of dynamo = 5 rpm
As output rpm of system is sufficient to develop electricity from dynamo
so our transmission design is safe & efficient.
In our project load is applied at shaft end by leaver. Manual load applied
by human is 20 kg. Length of lever is 400mm.
So Torque transmitted,
T = FxL
T= 20 x 9.81 x 400
T = 78480 N-mm
The same torque is transmitted to big gear shaft, as number of teeth on
both gears is same.
T = 3.14
16 x fs x Ds3
78480 = 3.14
16 x 170 x Ds3
Ds = 10 mm
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1 = T pulley shaft
2.76 78480
T pulley shaft = 28434.78 N mm
As torque on pulley shaft is less than torque on gear shaft so we take same
diameter of shaft on each Mountings for ease in manufacturing & selection of
bearing supports.
The spring is mounted on chain rack to make initial position of chain rack.
The outer diameter of spring is restricted due to size of chain rack, which is
20mm. We take the outer diameter of spring considering the clearance between
chain rack and spring to avoid jam of spring.
D = 20 + clearance between spring & chain rack
= 20 + 2mm
D = 22 mm
For average service life 422N/mm².
Wire diameter range is 4.5 to 8 mm
We get wire diameter d = 5 mm from range
Calculating the load bearing capacity of spring
Spring index = C = D/d = 22/5= 4.4
C = 4.4
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For C =4.4 K= 1.08
We know
Shear stress = 8KPD
3.14 d3
P = 422 x 3.14 x 53
8 x 1.08 x 22
P = 870.74 N
Applied load is limited to 200N
So the design of spring is safe.
As we required deflection of spring in the range of 125 to 150 mm
Spring rate = P/δ = 870.74 / 150 = 5.8 N /mm
K = 5.8 N/mm.
We know
δ = 8 P Do3N
G d4
150 = 8 x 870.74 x 223x N
0.007845 x 106 x 54
N = 10.68 Turns
N = 11 Turns
Ls = Nxd
= 11 x 5
= 55 mm
Free length of spring = Ls + mix + 0.015 x δ
= 55 + 150 + 0.15 x 150
Lf = 227.5 mm
Pitch of spring = free length
N
Pitch = 20
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9 MATERIALS USED AND THEIR PROPERTIES
a. Mild steel – EN – 4 to EN – 6
Carbon – 0.15% to 0.35%
Tensile strength –1200/1420MPA
Yield strength – 750/1170 MPA
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9.3 Plastic (Nylon):
Tensile strength – 82 N/mm2
Compressive strength – 35 N/mm2
Yield strength – 8500 psi
Rockwell Hardness Number R112-120
The plastics are synthetic materials which are moulded into shape under
pressure with or without the application of heat. These can also be cast, rolled,
extruded, laminated, and machined.
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10 PROCESS SHEET
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Part Name : Frame
Quantity :1
Material : M.S. Angle
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Part Name : Plate
Quantity :1
Material : M.S.
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Part Name : Pulley
Quantity :2
Material : C.I.
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11 COST ESTIMATION
1 Shaft 60 120
2 Bearing Mounter plate 60 60
3 Dynamo Mounter angle 60 30
4 Frame angle 60 420
5 Chain rack rod 60 60
6 Metal sheet 60 30
TOTAL 720/-
TOTAL 2100/-
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11.3 Cost Of Standard Parts
Sr.
Details Total Cost
No
1 Transport 400
2 Other/overhead 300
Total 700/-
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12 ACTIVITY CHART
Activity Chart
Month
December January February March
Activity
Project Discussion
with Coordinator
Group Formation
Topic Selection
Project Planning
about Design and
Manufacturing, Data
Collection
Actual Work Started
2 D Sketching in
AUTO CAD
Design and
Component
Selection
Procurement of
Parts
Manufacturing of
Model
Coloring
Report Preparation
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13 ADVANTAGES AND DISADVANTAGES
13.1 Advantages
13.2 Disadvantages
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14 FUTURE SCOPE
1. We can vary the size of the device using the various proportions for big
places like industries, colleges, malls etc.
2. We can install generator along with the arrangement of converting the
reciprocating motion to the rotary motion. This rotary motion is further
magnify using reciprocating motion in to rotary motion-belt & pulley
drive. The output of pulley is attached with flywheel it stored kinetic
energy and transfer to alternator which generate electricity with zero cost.
3. To operate the reciprocating compressor and produce high pressure air.
4. We can modify it to work as water lifting pump by installing the water
compressing reciprocating hydraulic pump.
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15 CONCLUSION
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16 PHOTO GALLERY
a. Half Axle
b. Chain Transmission
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c. Dynamo
d. Chain Mechanism
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e. Chain Rack
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g. Spring Suspension
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17 BIBLIOGRAPHY
17.2 Websites
1) www.wikipedia.com
2) www.howstuffworks.com
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