Savitribai Phule Pune University Multi Domain Energy Generation

1. INTRODUCTION
1.1 Background
The growing demand of power for a variety of human activities cannot be answered
without continuous efforts of exploring better options and application for sustainable energy
sources. Today power has become one of the major needs of human life however, one of the
fear of the generation is whether the current energy sources continue to generate the required
amount which has a progressive trend across generation. Hence, dreaming future days with
insufficient or no electricity makes the generation future very difficult or impossible.
Therefore, such conditions call an integrated research approach on power generation and it is
our responsibility to work and come up with a possible means of sustainable and green
energy production for satisfying our day to day progressive energy requirements and make
the planet earth a better place to live in.[1]
The day-to-day increasing population and decreasing quantity trend of conventional sources
for power generation, provides a need to think on other energy resources. States are working
toward the development of non-conventional sources for power generation. Due to the
reasons that conventional sources of power are releasing live risking by-products which are
causing huge problems to humans and all living things on the planet earth. They are getting
scarcer due to continuous exploitation of high amount. Energy harvesting is related to
developing a mechanism for driving energy from different sources and energy of today’s
world is mainly generated from conventional energy sources which mostly are decreasing
day by day. Moreover, these conventional energy sources cause pollution and are responsible
for global warming. To solve these problems, researchers are trying frequently to explore
new energy sources which are clean, environment friendly, sustainable, and promising in
order to meet the future electricity demand of the generation. And it is also essential to focus
more on renewable (unconventional) energy sources for electricity generation and it is also
paramount to think more specific to the utilization of kinetic energy which is helpful to
reducing dependence on conventional sources of electricity generation.[2]
1.2 PIEZOELECTRIC ARRANGEMENT :
Piezo generation is a new approach to generate electrical energy from the sensing cum
converting equipment called piezo sensor or piezo buzzer. It mainly works on a principle of
piezoelectric effect which is creating pressure energy crystaline material viz., quartz crystal to
generate electricity. Piezoelectric effect is discovered in 1880 by Jacques and Pierre Curie
during studies into the effect of pressure on generation of electrical charge by crystals.[3]

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1.3 PIEZOELECTRIC EFFECT :

Piezoelectricity is defined as change in electric polarization with change in applied stress
(Direct piezoelectric effect). The piezo material exhibits both “Direct piezoelectric effect” as
well as ‘converse piezoelectric effect’. Direct piezoelectric effect is the production of
electricity when the crystals are mechanically stressed and the converse piezoelectric effect is
the stress or strain in the crystal when an electric potential is applied. The most common
crystals used are lead zirconateTitanate crystals.[3]

Fig. 1.1 (a) Piezoelectric Mechanism Fig. 1.1 (b) Converse Piezo Mechanism

1.4 HOW IT WORKS ?

In a piezoelectric crystal, the positive and negative electrical charges are separated,
but symmetrically distributed. This makes crystal electrically neutral. Each of these sides
form an electric dipole and dipoles near each other tend to be aligned in regions called
“Weiss domains”. The domains are usually randomly oriented, but can be aligned during
poling, a process by which a strong electric field is applied across the material, usually at
elevated temperatures. When a mechanical stress is applied, this symmetry is disturbed and
the charge asymmetry generates across the material. In converse piezoelectric effect,
application of an electrical field creates mechanical deformation in the crystal.

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Fig 1.1 Piezoelectric cantilever model

The most common application of piezo crystals to generate a potential is the electric
cigarette lighter. Pressing the button of lighter causes a spring loaded hammer to hit a
piezoelectric crystal producing a sufficiently high voltage that electric current flows across a
small spark gap, thus heating and igniting the gas. Some substances like quartz can generate
potential differences of thousands of volts through direct piezoelectric effect.
Flexible piezoelectric materials are attractive for power harvesting applications
because of their ability to withstand large amount of strain. Larger strain provides more
mechanical energy available for conversion into electrical energy. A second method of
increasing the amount of energy harvested from piezoelectric is to utilize more efficient
coupling mode.

Fig. 1.2 Working Mechanism Of Simple Piezo Transducer.

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1.5 RACK AND PINION ARRANGEMENT:

In this project, we have also presented the design of power generation using
suspension system based on available piezoelectric sensors and Rack and Pinion Mechanism.
The suspension systems are used in vehicle to support weight of vehicle body and to isolate
the vehicle chassis from road disturbances. The dampers are designed to dissipate vibration
energy into heat so as to reduce the vibration transmitted from road excitation. It is feasible to
harvest this vibration energy from the vehicle suspension system to improve the efficiency of
the vehicle. The suspension system used for the regeneration of vibration energy is called
regenerative suspension system.

Fig.1.3 Rack and pinion

1.6 WORKING:

Fig.1.4 Working system

Vertical movement of rack in actual operation is happened due to suspension

movement. This movement of rack results in vertical movement of rack attached to the

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suspension frame. This rack drives the pinion meshing with it. On the pinion shaft 2nd gear is
mounted which rotates with same RPM as of the pinion speed. This 2nd gear drives the 3rd
gear having bigger dia. Of 98 mm mounted on 2nd shaft. On this 2nd shaft V-groove pulley
is mounted. Another pulley is mounted on alternator which is driven by belt drive. As
alternator shaft rotates it cuts the magnetic flux and EMF is generated at the output. This
EMF generated is used to glow the LED lamp, or we can measure the output voltage and
current by using DMM for analysis propose.
One of the promising options is by using piezoelectric material or PZT. PZT can be
used as a mechanism to transfer ambient vibrations into electrical energy. This energy can be
stored and used to power up electrical and electronics devices. With the recent advancement
in micro scale devices, PZT power generation can provide a conventional alternative to
traditional power sources used to operate certain types of sensors/actuators, telemetry, and
MEMS devices.
Piezoelectric materials act as a transducers and pressure exerted by the moving parts
transformed into electric current. We propose a design plan that converts the mechanical
energy in bikes to electrical energy much more efficiently than it has been done before.The
electricity generated will then be used to recharge the battery of bike for further use and
functioning of the bike.

1.7 BATTERY MANAGEMENT SYSTEM:

Fig 1.5 Specific energy and power of the main battery technology

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Battery management systems (BMS) have two main roles: the first one is to monitor the
battery to determine information such as its State of Charge, State of Health (the ability of the
battery to deliver its specified output) and Remaining Useful Life. These parameters are
crucial for users as well as to optimize the charge and discharge processes and must be
communicated to on-board systems (safety system, communication with the driver, engine
management). Different modelling methods have been proposed in the literature. The second
role is to operate the battery in a safe, efficient and non-damaging way. As can be seen,
battery blocks are composed of cells arranged in parallel and series to meet the needs of the
engine. As those cell characteristics can differ slightly, it is necessary to balance the charge
between each cell to prevent damage and improve the lifetime of the stack. Passive balancing
methods have been used, during charge, using dissipation through resistors, but it is not an
efficient solution. Second generation batteries will probably rely on active cell balancing, one
method being presented in.
1.8 SPRINGS :

Fig.1.6 Spring

Spring ID: 12mm

Spring OD: 14mm

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Length: 80mm
Pitch: 8mm
Wire dia: 1mm

The most widely used type of spring, compression springs are designed to
oppose compression and return to its uncompressed length when the applied force is
removed. The potential applications for compression springs are limited only by the
imagination.
Compression springs are devices made up of helically formed coils with pitch in
between used to push back on an applied force or load in order to return to its original position
when the force or load is released. They are the most commonly used type of spring as well as
the most economical. There are many types of compression springs used to fulfill certain
functions for many applications, devices, and/or mechanisms.
1.9 DC MOTOR

:
Fig.1.7 DC Motor

 Voltage: 12V DC supply

 Current: 2amp
 6mm shaft diameter with internal hole
 12 V DC motors with Gearbox
 Weight: 125grm

1.10 PROBLEM STATEMENT-

Nowadays much of the governments are working towards employing maximum
amount of electric vehicles due to increasing pollution and also the prices of fuels are rising.
As electric vehicles are better replacements for fossil fueled vehicles as they are pollution
free and low costs of electricity as compared to fuels. But the range of these vehicles is less
per full charge of the vehicle battery and are required to charge again and again, so we
propose a design plan to continuously charge the battery during running condition.

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1.11 OBJECTIVES:

 To design and develop vibrating mechanism in the bike for actuation of piezoelectric
sensors:
Mechanical compression or tension on poled piezoelectric ceramic element changes the di-pole
moment, creating a voltage. Compression along the direction of polarization or tension
perpendicular to direction of polarization generates voltage of the same polarity as poling
voltage.
The principle is adapted to piezoelectric motors, sound or ultra sound generating devices, and
many other products. Generator action is used in fuel ignition devices, solid state batteries
and other products; motor action is adapted to piezoelectric motors, sound or ultra sound
generating devices and many other products.

 To harvest the electrical energy generated from vibrations using piezo electric sensors:
It is an objective of the present idea to provide an ancillary source of energy having no power
supply unit, which converts vibration energy generated for charging a battery. According to
present idea a piezoelectric material is mounted below the keys of the particular device.
During key depression, the piezoelectric material is subjected to vibrations due to pressure
applied on the keys and therefore, the piezoelectric material is expanded or contracted. AC
voltage generated in the pair of electrodes provided in the piezoelectric material is rectified
and stored in capacitor. The charge has present in the capacitor is used for charging of
separate battery which is incorporated separately with main battery of the device. This
battery could be used during emergency situations for powering the device for short span.

1.12 SCOPE:
Increasing pollution is significant issue in the transport sector. Driving fossil fueled
vehicles causes serious amount of air pollution. Which leads to global warming. This issue is
encountered by employing electric vehicles. But the limited travelling range of these electric
vehicles restrict their use in majority. This issue can be overcome by employing mechanisms
like, vibrating mechanism for electricity generation from piezoelectric sensors along with
rack and pinion mechanism in different manners and locations on the bike.

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1.13 METHODOLOGY:
This study/project would be consisting of following chronological step of working:

1. Literature study
2. Project identification
3. Project literature study
4. Field work
5. Design stage
6. System drawing
7. Material procurement
8. Manufacturing stage
9. Fabrication of assembly
10. Trials and troubleshooting
11. Testing
12. Conclusion
13. Report and project presentation

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2. LITERATURE REVIEW
In the past few of the developments took place to sort out the problems regarding the
charging of electric vehicle batteries. This research was carried out in a different way by
different scholars and made technological amendments in it, some of them carried out it
electronically.

Henry A. Sodano, Daniel J. Inman and Gyuhae Park et.al.(2007) in their paper‘A Review
of Power Harvesting from Vibration using Piezoelectric Materials’ stated that the process
of acquiring the energy surrounding a system and converting it into usable electrical energy is
termed power harvesting. In the last few years, there has been a surge of research in the area
of power harvesting. This increase in research has been brought on by the modern advances
in wireless technology and low-power electronics such as micro-electro-mechanical systems.
It also presents the research that has been performed in the area of power harvesting and the
future goals that must be achieved for power harvesting systems to find their way into
everyday use. While piezoelectric materials are the major method of harvesting energy, other
methods do exist; for example, one of the conventional methods is the use of electromagnetic
devices. In this paper we discuss the research that has been performed in the area of power
harvesting and the future goals that must be achieved for power harvesting systems to find
their way into everyday use.

Nayan HR et.al.(2015)in his paper ‘Power Generation Using Piezoelectric Material’

published in ‘American International University, Dhaka, Bangladesh’ have stated that the
use of piezoelectric materials in order to harvest energy from people walking vibration for
generating and accumulating the energy. This concept is also applicable to some large
vibration sources which can find from nature. Micro energy also can produce from those
natural sources that are called micro energy harvesting. Micro energy harvesting technology
is based on mechanical vibration, mechanical stress and strain, thermal energy from furnace,
heaters and friction sources, sun light or room light, human body, chemical or biological
sources, which can generate mW or μW level power.
Dr V.R.Sastry, Raghuchandra Garimella and Mohammed Shoeb Mohiuddin et.al.
(2015) in their paper ‘Piezo-gen An approach to generate electricity from vibration’
published in Department of Mining Engineering, NITK-Surathkal, Mangalore, 575025,
Karnataka, India have stated that, with the help of a number of vibratory plates which are
well said to be piezo-sensors, the frequency of different unnecessary vibrations will be

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converted into alternating supply, and then it will be further converted into direct supply with
the help of ultra-fast switching diode. Experiments on the frequency of piezoelectric elements
are described with special reference to the effect due to supersonic sound waves generated in
the air gap of the holder and due to its capacity
Mr.Akshat Kamboj, Altamash Haque, Ayush Kumar, V. K. Sharma, and Arun Kumar
et.al.(2013) in their paper ‘Design of footstep power generator using piezoelectric
sensors’ have stated the design of power generation using footstep based on available
piezoelectric sensors. Extremely populated nations like China and India. Where the streets,
rail and bus station are over peopled and packed like sardines moving around the clock. So,
using such concept the power can be availed and deployed by converting mechanical energy
to electrical energy. Piezoelectric materials act as a transducers and pressure exerted by the
moving people transformed into electric current.
Chaitanya B. Lamdhade1,Rahul P. Khedkar , Vishal D. Hirgude, and Shubham V.
Gore et.al.(2017) in their paper ‘Energy Generation from Suspension System’ have stated
that Piezoelectric materials belong to class called ferroelectrics. One of the defining traits of
a ferroelectric material is that the molecular structure is oriented such that the material
exhibits a local charge separation, known as an electric dipole.Vibration energy of vehicle
suspension is dissipated as heat by shock absorber, which wastes a considerable number of
resources. Power Generating Shock Absorber brings hope for recycling the wasted energy.
Shubham R.Muley , Nitin M. Pandao, Pallavi M. Bhople ,Vishal P. Chatarkar, Krishna
G. Parihar et.al.(2017) in their paper ‘Power Generation Using Vehicle Suspension’
published in ‘International Journal of Research in Advent Technology’ stated that they use
shock absorber, rack & pinion arrangement and dynamo. As shock absorber effect formed,
spring is compressed. Linear movement of crank is converted into the rotary motion due to
pinion moves as the rack is meshed with pinion and the pinion is mounted on the shaft which
is connected to shaft of dynamo. Due to this arrangement, rotary motion of pinion is used to
rotate dynamo. As dynamo rotation leCds to generation of energy. And these energy is used
to charge the battery and these store energy is use for different vehicle accessories
Himanshu S. Rewatkar, Vicky R. Gedekar, Kunal L. Parate et.al. (2017)in their paper
‘Power Generation by Using Suspension System’published in ‘UG scholar, Department of
Mechanical Engineering, G.H. Raisoni College of Engineering, Nagpur, Maharashtra, India’
stated that to develop electricity using the real-time motion of parts in a form of wheeler.
After careful analysis of a various such parts it was decided to generated electricity using
relational motion available in a suspension system of a two wheeler.

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3. ACTION PLAN

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4. SAMPLE CALCULATIONS

4.1 Model Calculations:

Electrical Calculation When a vehicle is running at a speed of 20 to 30 km/hr we observe 6 to
9 volts with the help of multi meter. Voltage Generated (V) = 9 volt, Current Generated (I) =
3.2 amp
As Electrical Power (P) = V x I = 9 x 3.2 = 28.8 Watts
 TO CALCULATE CHARGING TIME FOR 6 VOLT BATTERY :
Charging time = battery current (Ah) / current generated (A)
= 4.5 (Ah) /3.2(A)
= 1.40 hr.
But it was noted that during charging 40% get loss
= 4.5 x 40 /100
= 1.8 Ah Charging time
= 4.5 +1.8 /3.2
=1.9 hr.
 TO CALCULATE CHARGING TIME FOR 12 VOLT BATTERY
Consider that the suspension system is mounted on both side of the front suspension. Total
voltage produced by this suspension system in 18 volt, 64A. Therefore time required to
charge a 12 volt, 33 Ah battery is,
Charging Time = Battery current (Ah) / current generated (A)
= 33 (Ah)/ 6.4 (A) =5.15 hr.
But it was noted that 40% loss during battery charging
= 33 x 40/100
= 13.2 (Ah)
Charging time = 33 + 13.2 /6.4
= 7.21 hr.

4.2 DESIGN CALCULATIONS :

Weight of vehicle = 202030 N

Radius of wheel= 51 cm

Total torque = Engine rating*gear ratio*SLR

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= 1220*12*4.5

= 65880 N-m

Since , 100% efficiency is not possible so, assuming 80% efficiency

Total torque = 0.8*65880

= 52704 N-M

Tractive force = T/R

= 52704/0.51

Tractive force for each wheel = 103341.17/4

= 25.83KN

Displacement of plate = 0.125 M

Speed of vehicle/plate = 60 Km/hr = 16.67m/sec

Assume:

Time required to move the plate for 0.125 m is 1 sec.

Pinion complete 1 rotation in 1 sec.

N = 60 rpm

4.3 Design of rack and pinion

Material for pinion = C45 ..... (1.12 PSG)

Sut = 700 N/mm2

Syt = 380 N/mm2

Assume no. of teeth on pinion at 20º pressure angle = 20

Zp = 20

σb = sut/3
= 700/3
= 233.33 N/mm2

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yp = 0.484-( 2.87/-zp)

= 0.487- (2.87/20)

= 0.3405

b = 10 m

Beam strength calculations

Fb = σb*b*m*yp

= 233.33*10m*m*0.3405

= 794.48m^2 N

Effective load :

V (pitch line velocity )

V = ( π*20*m*60)/60

= 0.06283 m/s

Ft = p/v

Now, Pi = input power

= force*displacement

= 25.83*103*0.125

Pi = 3228.75 watt

Since ,100 % power cannot be transmitted so assuming 80% efficiency.

Pi = 0.8*3228.75

= 2583 watt

Now, Ft = P/V

= 2583/0.0628*m

= 41110.93/m

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Newton Effective Force = Ka*Km*Ft/K

Now, Kv=3/3+v

= 3/3+0.0628*m

Service factor Ka = 2 ; Load distribution factor = 1

Feff (Effective Force) =2*1*41110.93*(3+0.0628m)/3*m

Considering factor of safety (Nf) = 2

(For case hardened) ....PSG 8.19, Table No. 20

Fb = Nf* Feff

794.48*m2 = 2*27407.28*(3+0.0628m)/m

m3-4.33m-206.98 = 0

Therefore, m = 6.15

By taking next step for module, module = 8 mm.

Dimensions of pinion :

Diameter of pinion = m*Zp

= 8*20

= 160 mm.

Addendum (ha) = 1*m

= 1*8

= 8 mm.

Deddendum (hf) = 1.25*m

= 1.25*8

= 10 mm.

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Design of rack:-

Module (m) = 8mm.

Pitch = *m

= * 8

= 25mm.

Total length of rack = 625 mm.

Number of teeth = 625/25

= 25

4.2.2 Design of shaft :

Centre distance between gear (a) = m*(Zp+Zr)/2

= 8*(20+25)/2

= 180mm.

Internal diameter of gear (d) = 0.3*a

= 0.3*180

= 55 mm.

On strength basis :-

Material for shaft = C45 PSG 1.10

Sut = 700 N/mm2

Syt = 380 N/mm2

BHN = 229

Input power (Pi) = 2583 watt

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Speed (N) =60rpm

Radial force (Fr) = Ft*tan = 25.83*103*tan(20)

But gears have hole of 55 mm.

So, Diameter of shaft = 55mm.

For tolerance, Choose IT7 grade.

IT7=10i

i = 0.45(D)^(1/3)+0.001D

i = 0.45(55)^(1/3)+0.001(55)

i = 1.76um

= 1.76*10^(-3)mm

16i =16*1.76*10^ (-3)

16 IT7=Tolerance =0.028 =0.028mm

4.2.3 Design of key :

Material same as shaft.

Assume rectangular key of,

t = thickness = d/6 W
= d/4.

(a) Considering shear failure of key,

T = (w*L*Fs)*(d/2)(10^3)*5655.76

= (55/4)*L1*350*(55/2) L1

= 42.75mm~=50mm

(b) Considering crushing failure of key,

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σc = 4t/dhl

σc = syt/Nf

σc = σt =700 N/mm^2.

Fr=9401.35 N

Fs=350 N/mm^2

σt =700 N/mm^2

Kb=2……combine shock and fatigue factor for bending

Kt=2…..combine shock and fatigue factor for Torsion.

P= 2Πnt / 60=2π*60*T/60

T=411.09 N.m……..Torque.

Bending moment ,
M=f*L/4

M=9401.35*1.2/4

M=405 N.m

Equivalent Torque ,

Teq = √[(Kt*T)^2+(Kb*M)^2]

Teq = √[1*411.09)^2+(2*2820.405)^2]

Teq = 5655.76 Nm

Teq = (π/16*d^3*fs max)

Fmax = Fs … permissible

10^3*5655.76 = (π/16)*d^3*350

d = 43.49 mm

L = 700*55*55/6

= 4*5655.76*1063/l

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L = 64.135 mm ≈ 65 mm

4.4 Selection of Bearing:-

Ln =25000 hours,

Continues operation .…..PSG 4.3

Now,

Fr = 9401.35 N

Fa = 0 .

So, Pe = [XVFr + YFa]*Ka

where,
X=1 equivalent load bearing ………………….PSG 4.4

Ka = 2[machine with moderate shake impact ]

Pe = z*1 *9401.35 *2

= 18802.7N.

Life of Bearing ,

L10= Lh10*60*n/106

L10= 25000*60*60/106

L10= 90 million revolutions.

Using load-life relationship ,

L10 = (e/p)^10/3

903/10 * 18802.7 = C

Cr = 72525.87 N.

Now,

C = 78500 N

So, Hence Bearing No. 6411 is selected

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Deep groove ball bearing ….. PSG 4.15

Co = 64000 N,

Do =140 mm ,

r = 3.5 mm ,

r1 = 2 mm

D1 = 69 mm .

No of bearing = 2 .

4.5 Spring design :

Load =25.83 * 103 N

We have to use two springs.

Load on each spring = 25830 / 2

=12915 N

Mostly, material used for helical compression spring carbon steel (Oil hardened and tempered
condition. )

Material Selection :- ………………..…….PSG 1.10

C65 is selected

C (%) =0.65

Mn (%)= 0.75

Tensile Strength = 1380 N / mm2

Yield Stress = 430 N/mm2 .

d=7mm

Spring index [ c] = 5.4

C= D/d

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5.4*7 =D

D=37.8 mm

d = 7 mm is not applicable

So, d = 7*4 = 28 mm

C = D/d = D/28

D = 151 mm

deflection of spring = 125 mm

total length of spring = 250 mm

i) Solid length = (Ls) = n’ d

= ( 125/28) = n’

n’ = 4.46 = 5 turns

Total no. of coils = 5

ii) free length ( Lf) = 250 mm

Lf = Ls+ δmax+ 0.15 δmax

250 = 125 + 1.15 δmax

δmax = 108.69

iii). spring stiffness (K) :

K = F/δ

= 12915/125

= 103.32 N/mm

iv) Inactive coils & active coils :

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For square and ground end

n’ = n+2

5-2 = n

n = 3 turns (active)

2 ( inactive coils)

Design calculations :

d = dia. Of spring wire

= 28 mm

D = mean dia. Of spring

= 151 mm

n = no. Of active coils

= 3 turns

n’ = total no. Of coils

= 5 turns

δ = axial deflection due to load

= 125 mm

fs = 0.75( 0.18*sut )

Or = 0.75 ( 0.3*sut ) ......... select smaller of two values

Hence, 186 N/mm2 and 96.75 N/mm2

fs = shear stress

= 96.75 N/mm2

G = modulus of rigidity of material

= 77*103 N/mm2

C = spring stiffness

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= 5.4

P = ( pitch )

= Lf/( n’- 1)

= 250/( 5 – 1)

P = 62.5 mm

A) Torque produce in wire:

T = ( w*D)/2

= (12915*151) /2

T = 975082.5 N-mm ..........(1)

We also know,

T = ( π/16)*d3*fs ..........(2)

From eqn. (1) & (2)

Fs = (8wD/ πd3)

= 8*12915*151 /(π*28^3)

Fs1 = 226.22 N/mm2

(B) Direct Stress Fs2 due to load

Fs2 = W/(π/4)d2

= 12915/(π/4)*28^2

=20.97 N/mm2

Total Resultant Stress [Shear]

Fs=[(4C-1)/(4C-4)]+0.615/C

=1.284

Total stress formulae

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Fs=k*(8WD)/πd3

=1.284*8*12915*151/(π*28^3)

=290.47 N/mm2
[2] Deflection of helical spring

D = 37.50 mm
But we required deflection of 125 mm, so

D = 225.40 mm

Now , Corrected spring index ,C = D/d

C = 225.40/28

C = 8.05

Corrected total stress in spring ,

K = (4C-1)/(4C-4)+0.615/C K = 1.18

Fs = K*(8WD/πd3)

= 1.18*8*12915*225.40/(π*28^3)

Fs = 398.47 N/mm2

4.6 MATERIAL COST

RAW MATERIAL COST
The total raw material cost as per the individual materials and their corresponding rates per
kg is as follows,
Total raw material cost = Rs. 2000
Table 4.1 – Machining Cost
OPERATION RATE TOTAL TIME TOTAL
Rs /HR HRS COST Rs/-
LASER 350 1 350
CUTTING
DRILLING 100 1 100
TAPPING 100 1 100
TOTAL Rs. 550

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Table 4.3 – Cost of Purchased Parts

SR DESCRIPTION QTY COST
NO.
1. BEARINGS 02 100
2. MOTOR 01 200
3. GENERATOR 02 400
4. BATTERY 01 700
5. VOLTAGE BOOSTING 01 1000
CIRCUIT

MISCELLNEOUS COST
Overhead + Handling charges = 1000

TOTAL COST
TOTAL COST = Raw Material Cost +Machine Cost + Cost of Purchased Parts +
Miscellaneous Cost

Hence the total cost of machine = Rs. 5950 /-

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5. OBSERVATION TABLE

Sr.No. Input Output

Current (Amp) Voltage (Volts)
0.25 1.6
01 At Generator 0.39 1.8
0.32 1.7
0.07 10
02 At Piezoelectric sensor 0.1 14
0.09 13
0.45 3.45
03 At Rack and Pinion 0.49 4.12
0.52 4.73
Total 0.4 – 0.55 13 - 16

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6. PROJECT DRAWING -

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7. CONCLUSION:
 In this work information regarding production of electricity by the application of piezoelectric
sensors and rack and pinion arrangement is studied.
 Vibrational energy treated as waste form of energy until yet. Since electrical energy produced
by other sources is non-renewable hence the electrical energy is saved efficiently and
effectively.

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8. FUTURE SCOPE:
The developed mechanism can generate electricity when the vehicle is in running condition
which is used to continuously charge the battery.
The modifications that can be done in this project are:
 The piezo electric sensors can be added on the suspension systems to further enhance
the voltage and current input to the battery.
 With the advancement in the material technology, the design strength should be so
given that the mechanism can work for longer period of time without failure.
 The production of energy can be optimized by changing the geometry, increasing the
number of damping cylinders, by changing the boundary condition.
 Methods of increasing the amount of energy generated by the power harvesting device
or developing new and innovative methods of accumulating the energy are the key
technologies that will allow power harvesting to become a source of power for
portable electronics and wireless sensors.

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9.REFERENCES :
[1]. Henry A. Sodano, Daniel J. Inman and Gyuhae Park,A Review of Power Harvesting
from Vibration using Piezoelectric Materials (2007)
[2].Nayan HR, Power Generation Using Piezoelectric Material (2015)
[3].Dr V.R.Sastry, RaghuchandraGarimella and Mohammed ShoebMohiuddin,Piezo-gen An
approach to generate electricity from vibration (2015).
[4].Mr. AkshatKamboj, AltamashHaque, Ayush Kumar, V. K. Sharma, and Arun Kumar,
Design of footstep power generator using piezoelectric sensors. (2013)
[5]. Chaitanya B. Lamdhade1,Rahul P. Khedkar , Vishal D. Hirgude, and Shubham V.
Gore,Energy Generation from Suspension System.(2017)
[6]. ShubhamR.Muley , Nitin M. Pandao, Pallavi M. Bhople ,Vishal P. Chatarkar, Krishna G.
Parihar,Power Generation Using Vehicle Suspension (2017)
[7].Himanshu S. Rewatkar, Vicky R. Gedekar, Kunal L. Parate, Power Generation by Using
Suspension System (2017)
[8]. Nicola Heidrich, FabierKnobberVlalamirpolyakov,corrugated piezoelectric membranes
from energy harvesting from aperiodic motion (2013).
[9]. J. John Livingston* and M. Hemalatha, Charging an Electronic Gadget using
Piezoelectricity (2014).
[10]. SunaJu, Chang-HyeonJi, Impact-based piezoelectric vibration energy harvester (2018).
[11]. Amin MahmoudzadehAndwaria, ApostolosPesiridis et.al Review of Battery Electric
Vehicle technology and readiness levels(2017)

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