Elect o Generator

Electro Generator By Two-Stage Mechanical Oscillator
CHAPTER -1
NEED FOR PROJECT
P.C. POLY, MECHANICAL DEPT. 1

1. NEED FOR PROJECT
1.1 Total Energy
Our total energy use can be divided into three principal areas each of which consume
approximately equal amounts of energy on an annual basis:
 Electricity Generation
 Space Heating
 Transportation
This energy use has been roughly constant over the last 5 years and is dominated
(90%) by the use of fossil fuels.

Fossil Fuels come in 3 principal forms from which many other products are derived:
 Coal
 Natural Gas
 Crude Oil
Most traditional Energy production comes about via steam driven turbines so the
heating of water is what is essential.
 Coal Fired Steam Plants

 Nuclear Fired Steam Plants
 Oil/Natural Gas Fired Steam Plants

1.2 The Need for Alternative Energy
 Basic concept of alternative energy sources relates to issues of sustainability,

renewability and pollution reduction.
 In reality, Alternative Energy means any thing other than deriving energy via
Fossil Fuel combustion
 Basic Barrier to all forms of alternative energy lies in initial costs!
 Currently we have no significant production line alternative energy source

operating anywhere in the US!
The simple problem is that there are simply not enough fossil fuels left to
sustain its usage as the foundation of our energy production. Forget about global
warming for the moment, the issue is more basic than that.
We have about 50 more years of production from known reserves , after that
we will either have to discover more reserves are shift away from our fossil fuel based
energy economy. Thus there is a need to find new and innovative methods of energy
generation or to improve the existing methods of renewable form of energy tapping to
make them efficient and economical…..The Electro-generator using two stage
mechanical oscillator is one more step in this direction…

CHAPTER – 2
CONCEPT OVERVIEW

2. CONCEPT OVERVIEW
The first part of this machine is a “simple machine” called a lever and
fulcrum. It functions as a balance beam resting on a low-friction bearing system, with
one fixed weight on either side of the beam. This part of the machine is oriented in the
horizontal plane, and can rock up and down within a limited range. This limited
horizontal movement is best defined by physical “stops” and limited to less than 15
degrees of rotation. Likewise, this movement is best “damped” by adding springs on
both the top and bottom of the beam to constantly center the beam at the mid-point of
its movement, and to return energy to it when the beam approaches the extremes of its
movement range. This creates a mechanical oscillator that has mass, inertia, and an
inherent frequency of oscillation based on its physical constants. This is the first of
two oscillators in the system.
The second component of the machine is a weighted pendulum. One of the

fixed weights is replaced with a weighted pendulum of equal mass hanging from the
beam on one side. Ideally, it should be attached to the balance beam by a low-friction
bearing mount whose position can be adjusted along the length of the beam. This
weighted pendulum defines a second oscillatory system in the vertical plane, and is
free to swing back and forth within a defined range. The swing of the pendulum is
“undamped”, and left able to swing completely free in the gravitational field for no
less than 90 degrees of rotation, and up to 180 degrees of rotation. The weighted
pendulum defines a second mechanical oscillator that has mass, inertia, and an
inherent frequency based on its physical constants.
The combining of these two, separate mechanical oscillators into a single

system becomes a “Two-stage Mechanical Oscillator”. When properly tuned, this
machine can function as a Mechanical Amplifier.

As with many of these types of motors and mechanisms, trying to understand

exactly how they produce energy can be confusing without building one. When a
Milkovic type oscillator is first assembled and operated, it behaves much like the
theoretical model would be expected to behave. The output is erratic and weak, the
pendulum is difficult to keep going and the whole thing is an inefficient mess.
However, it’s a whole different machine once it falls into resonance.
The output becomes strong and regular, the pendulum takes very little energy
to keep it swinging and you can see immediately what Milkovic is talking about. You
really need to build one and test it to get a better understanding of the principal
involved. Then you can try and get it into resonance, which will teach you in no
uncertain way the difference between a resonant and a non-resonant device
Electro-generator …Built –Up
Note : Arrangement shows elements 1&2 have relative motion between themselves as
a result of two-stage mechanical oscillator action…..this motion is utilized to run
dynamo using rack –pinion-flywheel & dynamo to produce electricity

This is basically a balance beam where the heavier side of the balance by
where 2 is balanced by the pendulum connected to it at 4. 3 is the pivot point and 1 is
like an anvil for the hammer to swing down upon.As 4 swings towards the left, it gets
to a point at the top of its swing right before it swings back where it is weightless for a
split second. At this exact moment, the the left end of the beam is much heavier and
will smack down upon the anvil. Pendulum swings to the right being assisted by the
force of GRAVITY and this balance out the beam for a moment so the hammer lifts
up in balance with the pendulum, but the gravity assistance makes the pendulum side
a heavier since there is added force in the momentum. The pendulum swings up
towards the right side and at the moment the pendulum meets the top of its swing to
the right, at the moment before it swings back down, it becomes weightless and the
left side of the beam smacks down hard on the anvil.
The pendulum swings down and assisted with momentum and force of gravity
makes it heavier than left side of beam and causes the hammer to lift up then
pendulum goes to top of swing to left and then becomes weightless the hammer
swings down. This isn't perpetual motion, when the pendulum is swung, if just left
along WILL come to a dead stop...this isn't the point.
The point is that the OPPOSITE reaction helps the pendulum move in the
other direction that causes continued motion of the hammer to move up and down.
For each full swing in one direction and back to where it was, you get TWO FULL
hammer smacks for each full swing of the pendulum. It take VERY LITTLE power to
keep the pendulum swinging but you get an enormous amount of work at the anvil
side! This is an OPEN SYSTEM and all the work necessary to put into the system is a
little bit of fly power to keep the pendulum swinging, which is virtually nothing.
However, the work of the hammer on the anvil is about TWELVE times more than the
input to the pendulum. It is open to the environment utilizing gravity to help power
the system, swinging momentum assisted by gravity and other external forces.
This is 12.0 COP meaning 12 times more work is done than the operator has to
input to the system of just getting the pendulum to swing. This does NOT mean it is
over 100% efficient. It may be 99% efficient and there are still losses. Losses are the
pendulum swinging against air resistance, friction on the pivot point, etc... Efficiency
equals ALL the input energy. So conservation of energy is still "obeyed". What the

operator puts in (a little bit of fly power) + what the environment puts in GRAVITY =
total input. This compared to amount of work being done. That will probably be in the
high 90%'s. COP is total operator input (little bit of fly power) compared to all the
work being done and is about 12 times more than the operator puts in so is 1200% of
the input by operator. This is a 12.0 COP the rest of the input energy is from the
environment.
Fig 2.1 Working Diagram of Project

CHAPTER -3
BLOCK DIAGRAM OF PROJECT &

IT’S DESCRIPTION

3.1 Block Diagram of Project
Fig 3.1 Block Diagram of Project

3.2 Description of Block Diagram
Vehicle moves over metallic hump-hump moves down to rotate the pinion and
thereby the crank shaft by the rack and pinion arrangement which will cause the
driven link to oscillate one way clutch will make the pendulum to rise to highest level
Pendulum releases at this point and pendulum continues to oscillate for long amount
of time well after the next vehicle moves over hump.
The oscillation of the pendulum is given to the Two stage mechanical

oscillator mechanism which converts theses oscillation in to and fro motion of the
dynamo rack which drive the dynamo pinion which produces electricity for every
stroke of the pendulum system long after the first input was supplied.

CHAPTER – 4
BILL OF MATERIAL

4. BILL OF MATERIAL
SRNO PART DESCRIPTION QTY MATERIAL TOTAL

CODE RATE
(IN RS.)
1. NBM -1 ELECTRO-GENRATOR 01 STD 350
2. NBM -2 RACK 01 CI 350
3. NBM -3 PINION 01 STD 320
4. NBM -4 GUIDE 01 CI 300
5. NBM -5 MAIN SHAFT 01 EN24 350
6. NBM -6 ECCENTRIC CAM 01 EN24 450
7. NBM -7 JOCKEY 01 EN9 280
8. NBM –8 LH_BRG_HOUSING 01 EN9 250
9. NBM –9 RH_BRG_HOUSING 01 EN9 250
10. NBM –10 POS BALL SCREW 01 STD 550
11. NBM –11 HINGE PIN-1 01 EN24 200
12. NBM –12 FORK 01 EN9 400
13. NBM –13 TOP ARM 01 EN9 450
14. NBM –14 BOTTOM ARM 01 EN9 450
15. NBM –15 HINGE PLATES 02 EN9 800
16. NBM –16 GM BUSH 02 EN9 600
17. NBM –17 PENDULUM 01 EN9 600
18. NBM –18 PENDULUM HOLDER 02 EN9 500
19. NBM –19 ONE WAY CLUTCH 02 STD 1100
20. NBM -20 BASE FRAME 01 MS 500
21. NBM -21 BRG 6006ZZ 01 STD 600
22. NBM -22 SPRING 01 SPRING 150
STEEL
23. NBM -23 CIRCLIP 01 STD 550
24. -- OTHERS -- -- 1870
TOTAL COST 13,600
4.1 Estimate of Project (Approximate)
1. Raw material cost = 2800/-

2. Machining cost = 2600/-
3. Fabrication cost = 1500/-
4. Cost of std. parts
a. Motor = 1200/-
b. Bearings – 500/-
c. Tool & other hardware = 600/-

d. Dynamo : 1600
5. Miscellaneous cost = 800/-
Total estimate of project =18260/
4.2 Facilities Available/Reqd.
Infrastructure And Machinery Required
1. Lathe
2. Milling
3. Drilling
4. Electrical arc welding
5. DRO milling machine
6. Hobbing machine
4.3 Man Power Required
1. Turner
2. Miller
3. Machinist
4. Welder.

CHAPTER- 5
RESULTS & DISCUSSION

(PROPOSED WORK)

5. RESULTS & DISCUSSION (PROPOSED WORK)
1. Design & development of Twin stage oscillator system.

2. Application of the twin stage oscillator to speed breaker energy generator.
3. Main objective of the project is to demonstrate and prove that kinetic energy is
recovered by the above pendulum system…this is done using an electric lamp.
4. The quantification of the energy recovered can be done using an multi-meter
to measure current and voltage output from dynamo.
This can be done at different input conditions is by varying input motor speed
thereby the energy recovered at various vehicle speeds can be determined.

CHAPTER – 6
DESIGN METHODOLOGY

6. DESIGN METHODOLOGY
6.1 Design Of See-Saw Power Generator
In our attempt to design a special purpose machine we have adopted a very a

very careful approach, the total design work has been divided into two parts mainly;
 System design
 Mechanical design
System design mainly concerns with the various physical constraints and
ergonomics , space requirements, arrangement of various components on the main
frame of machine no of controls position of these controls ease of maintenance scope
of further improvement ; weight of m/c from ground etc.
6.2 In Mechanical design the component in two categories.
 Design parts
 Parts to be purchased.
For design parts detail design is done and dimensions thus obtained are
compared to next highest dimension which are readily available in market this
simplifies the assembly as well as post production servicing work.
The various tolerance on work are specified in the manufacturing drawings

the process charts are prepared & passed on to the manufacturing stage .The parts are
to be purchased directly are specified &selected from standard catalogues.

6.3 System Design

In system design we mainly concentrate on the following parameter
6.3.1. System selection based on physical constraints:-
While selecting any m/c it must be checked whether it is going to be used in

large scale or small scale industry In our care it is to be used in small scale industry
So space is a major constrain .The system is to be very compact it can be adjusted to
corner of a room.
The mechanical design has direct norms with the system design hence the
foremost job is to control the physical parameters so that the distinction obtained after
mechanical design can be well fitted into that.
6.3.2. Arrangement of various component
Keeping into view the space restriction the components should be laid such
that their easy removal or servicing is possible moreover every component should be
easily seen & none should be hidden every possible space is utilized in component
arrangement.
6.3.3. Components of system
As already stated system should be compact enough so that it can be

accommodated at a corner of a room. All the moving parts should be well closed &
compact A compact system gives a better look & structure.
6.3.4. Man –m/c Interaction
The friendliness of m/c with the operation is an important criterion of design.

It is application of anatomical
Following are some e.g. of this section
 Design of machine height

 Energy expenditure in hand operation
 Lighting condition of m/c

6.3.5. Chances of failure
The losses incurred by owner in case of failure of a component are important

criteria of design. Factor of safety while doing the mechanical design is kept high so
that there are less chances of failure there over periodic maintenance is required to
keep the m/c trouble free.
6.3.6. Servicing facility
The layout of components should be such that easy servicing is possible

especially those components which required frequent servicing can be easily
disassembled.
6.3.7. Scope of future improvement
Arrangement should be provided to expand the scope of work in future such

as to convert the m/c motor operated this system can be easy configured to required
one.
6.3.8. Height of m/c from ground
Fore ease and comfort of operator the height of m/c should be properly
decided so that he may not get tired during operation .The m/c should be slightly
higher than that the level also enough clearance be provided from ground for cleaning
purpose.
6.3.9. Weight of machine
The total wt of m/c depends upon the selection of material components as well
as dimension of components. A higher weighted m/c is difficult for transportation &
in case of major break down it becomes difficult to repair.
6.3 Mechanical Design

Mechanical design phase is very important from the view of designer .as
whole success of the project depends on the correct deign analysis of the problem.
Many preliminary alternatives are eliminated during this phase. Designer

should have adequate knowledge above physical properties of material, loads stresses,
deformation, failure. Theories and wear analysis , He should identify the external and
internal forces acting on the machine parts
6.3.1 These forces may be classified as ;
a) Dead weight forces

b) Friction forces
c) Inertia forces
d) Centrifugal forces
e) Forces generated during power transmission etc
Designer should estimate these forces very accurately by using design

equations .If he does not have sufficient information to estimate them he should make
certain practical assumptions based on similar conditions
which will almost satisfy the functional needs. Assumptions must always be
on the safer side.
Selection of factors of safety to find working or design stress is another

important step in design of working dimensions of machine elements. The correction
in the theoretical stress values are to be made according in the kind of loads, shape of
parts & service requirements.
Selection of material should be made according to the condition of loading

shapes of products environment conditions & desirable properties of material.
Provision should be made to minimize nearly adopting proper lubrications methods.
In ,mechanical design the components are listed down & stored on the basis of
their procurement in two categories

 Design parts
 Parts to be purchased
For design parts a detailed design is done & designation thus obtain are
compared to the next highest dimension which is ready available in market.
This simplification the assembly as well as post production service work. The
various tolerance on the work are specified. The process charts are prepared & passed
on to the work are specified.
The parts to be purchased directly are selected from various catalogues &
specification so that any body can purchased the same from the retail shop with the
given specifications.
6.4 Design Of The Top Arm Lever
MATERIAL SELECTION : -
Ref :- PSG (1.10 & 1.12) + (1.17)
DESIGNATION ULTIMATE TENSILE YEILD STRENGTH

STRENGTH N/mm2
N/mm2
650 480
EN 9
Cross section of link may be determined by considering lever in bending ;

The linkage has an section of (32 x 10 )mm
Let; t= thickness of link
B= width of link
Bending moment;
Section modules; Z= 1/6 t b2
Fb=m/z = PL
1/6 t B2
= 6PL
tB2

Maximum effort applied by hand( P)= 100 N
fb= 6 x 100 x 120

10 x 32 2
fb =7.03 N/mm2
As fbact< fball
Thus selecting an (32 x 10) cross-section for the link.
6.5 Design Of Spur Pinion & Gear Sector

Stage 1: Drive as GEAR and pinion arrangement
Maximum load =1250 N

b = 10 m
Sult pinion = Sult rack = 600 N/mm2
Service factor (Cs) = 1.5
The gear sector and pinion arrangement where as pinion has 12 teeth and gear sector
has 70 teeth (complete gear 140 teeth), as two pinions share the entire tooth load…
Pt = 1250/2 = 625 N.
Peff = 625 N (as Cv =1 due to low speed of operation)
Peff = 625 N --------(A)
Lewis Strength equation
WT = Sbym
Where ;
Y= 0.484 – 2.86
Z
 yp = 0.484 - 2.86 = 0.341
20
yg = 0.484 – 2.86 = 0.484

80
 Syp = 68.2
Syg = 89.6
As Syp < Sys  pinion is weaker

WT = (Syp ) x b x m

=68.2 x 10m x m
WT= 682 m2----------(B)
Equation (A) & (B)
682 m2 = 625
 m=0.95
selecting standard module = 2 MM
6.6 Design Of Main Shaft.
MATERIAL SELECTION : -
Ref :- PSG (1.10 & 1.12) + (1.17)
DESIGNATION ULTIMATE TENSILE YEILD STRENGTH

STRENGTH N/mm2 N/mm2
800 680
EN 24
6.7 Asme Code For Design Of Shaft.

Since the loads on most shafts in connected machinery are not constant , it is
necessary to make proper allowance for the harmful effects of load fluctuations
According to ASME code permissible values of shear stress may be calculated

form various relation.
= 0.18 x 800
= 144 N/mm2
OR
fs max = 0.3 fyt
=0.3 x 680 =204 N/mm
considering minimum of the above values ;
 fs max = 144 N/mm2

Shaft is provided with key way; this will reduce its strength. Hence reducing
above value of allowable stress by 25%

 fs max = 108 N/mm2

This is the allowable value of shear stress that can be induced in the shaft
material for safe operation.
To Calculate Shaft Torque
 T = 1250 N-mm
 T design = 1.25N-m
6.8 Check For Torsional Shear Failure Of Shaft.
Assuming minimum section diameter on input shaft = 16 mm
 d = 16 mm
Td = /16 x fs act x d3
 fs act = 16 x Td
 xd3
= 16 x 1.25 x 10 3
 x (16) 3
 fs act = 1.55 N/mm2

As fs act < fs all
 I/P shaft is safe under torsional load
6.9 Design Of Key

Selecting parallel key from standard data book for given application .
For Shaft Above 17

Diameter upto 22
Key cross section Width 6
Height 6
Material of key ‘EN9’

Sult = 520 N/mm2
Sylt = 340 N/mm2
 fs all = 85 N/mm2
 fs all = 170 N/mm2

 selecting parallel key;

6 x 6 x 30
 Check for direct shear failure of key:-
T = L x d/2 x t/2 x fs act
 24 x 103 = 30 x 6x 20 x fs act
2
 fs act = 1.25 x 103 x 2

30 x 6 x 20
 fs act = 0.70 N.mm2

As fs act < fs all
 Key is safe under shear load

 Check for crushing failure of key
T = Lx d/2 x t/2 x fs act

24x103 = 30 x 20/2 x 6/2 x fs act
 fs act = 1.25 X 103X 2 X 2

30 X 20 X 6
 fs act = 1.4 N.mm2

As fs act < fs all
 Key is safe under crushing load
6.10 Design (Selection Of Main Shaftball Brg)

In selection of ball bearing the main governing factor is the system design of
the drive ie; the size of the ball bearing is of major importance ; hence we shall first
select an appropriate ball bearing first select an appropriate ball bearing first taking
into consideration convinience of mounting the planetary pins and then we shall check
for the actual life of ball bearing .
6.11 Ball Bearing Selection.

Series 62

ISI NO Brg Basic d D1 D D2 B Basic capacity

Design No
(SKF)
C kgf Co Kgf
25B C02 6205 25 31 52 46 15 7100 11000
P = X Fr + Yfa.
Where ;
P=Equivalent dynamic load ,(N)
X=Radial load constant
Fr= Radial load(H)
Y = Axial load contact
Fa = Axial load (N)
In our case;
Radial load FR= 750N
Axial load Fa = Maximum table load = 60 kg =600 N
P= 1 x 750 +1 x 600 =1350 N
L= (C/p) p
Considering 4000 working hours
L = 60 n L h = 4.8 mrev
106 3
 4.8 = C
1350
 C = 2277 N
AS; required dynamic of bearing is less than the rated dynamic capacity of bearing ;
 Bearing is safe.
6.12 Mechanical Design

Design of Main Shaft

In designing the main shaft we have to take diameter of out put shaft
corresponding to the bore on the hub of magneto.
Let us assume that diameter of cup shaft (d)
D=12mm
Material selection :-
DESIGNATION TENSILE YEILD STRENGTH

STRENGTH N/MM2 N/MM2
C45 520 340

(COLD DRAWN)
USING ASME code to determine allowable shear stress

Fsall = 0.30 Syt =102 N/mm2
Fsall=0.18 Sult=93.6N/mm2
Considering the minimum value of the above
Fsall =93.6 =93N/mm2
Providing key way on shaft to hold the magnetic hub;
25% reduction in above value
Fsall = 0.75 x93
70 N/mm2
Calculation the torque on output shaft;
P= 2NT
60
We know that the shaft transmits 10 watt power at 780 rpm;
10 = 2x x 780xT

60
 T= 10x60
2N

T= 10 x 60
2xx780
T=0.1224 N-mm
T=122.42N-mm
Assuming 25% over load on shaft;
T design = 1.25 T
=1.25 x 122.42
T design = 153.025 N-mm
Check for torsional shear failure of shaft:-
T=/16 fsact x d3
153.025=/16 x fsact x(12)3
fsact = 16 x 153.025
x (12)3
fsact =0.451 N/mm2
fsact (0.451N/mm2) < fsall (70N/mm2)
 The out put shaft is safe in torsion.
Diameter of Cup shaft=12mm
A) Design of push rod
Let us design the piston rod in compression
The load acting on the piston rod =2500 N
Selection of material Ref: PSQ 1.10&1.12
Designation Tensile Yeild strength N/mm2

StrengthN/mm2
C40 680 380

Theoretical compressive stress
Fcall = Tensile strength
Factor of safety
= 680 =85 N/mm2
Check for failure of displacement rod in compression
/4 x d2 x fc act = 2500
fc act = 2500 / (/4 x 162 )
fc act =12.4339 N/mm2
as fc act <fc all
design is safe.
Design of spring
Deflection = 75 mm
Spring index =5
Maximumm permissible stress = 420 N/mm2
Modulus of rigidity = 84 KN/mm2
Whals correction factor =K= 4c-1 + 0.615
4c-4 C
K = 4(5) -1 + 0.615 =1.123

4(5)-1 5
Maximum stress
Fs = K x 8 Wc
 d2
420 = 1.123 x 8 x 1250 x 5

 x d2
 d= 6.5mm
Take standard wire having dia = 6.5mm

 Mean diameter of coin = 5x 6.5 = 32.5 mm

Outer diameter of coil = D+d =32.5+6.5 =39 mm
No of turns of coil ∂= 8w C3 n
Gxd
n = 84 x 103 x 6.5 x 75
8 x 1250 x 53
n = 33 turns
For squared and ground ends, the total number of turns ,
N=n+2
= 3 3+ 2 = 37 turns.
6.13 Design Of Roller Type Unidrirectional Clutch
Design of roller type unidirectional clutch will depend upon the design torque;
Tdesign = 954.92 N.mm
=954.92 x 75%
=954.92 x 1.75
Tdesign =1.65786 x 103 N.mm
Using PSG Design data;
Let us first select an appropriate roller clutch to transmit the above torque,
Roller clutch Terminology
Mt Transmitted Torque (kgf .cm)
Z No of rollers
R Inner radius pf outer ring ,cm
Ft Tangential force kgf
Fn Normal force kgf
µ Angle between runner surface &fgt
b friction angle (µ/2)

D Diameter of roller
Po Pressure on projected area of roller
Mb1 Bent moment on ring

Rm Mean radius
T Thickness of ring
B bending stress
b1 Width of ring
Y Deformation of
K1 k2 constant depending
Z1 Modulus of ring
Design of roller
We know that ;
A= ( R – d ) cos µ - d
2 2
Where; R = do/2t
Now ; t = thickness of ring.
t= C2 + C2D
2
and C2 = 3 C1 f = C3 f
fb x b b
Reffering design data,
Z C1 C3 for K1 K2
B= 200
Okgf/cm2
6 0.089 1.34 x 104 0.96 x 10-8 5.62 x 10-7
Width of roller clutch = Length of roller = 20mm

b = 2 cm
Now;
Torque =Force x radius
1.65786 x103 = F x Do
2
F = 30.14 N
=3.014 kgf
Now substituting f in equation (2)

C2 = C3 x F
B
C2 = 1.34 x 3.014 x 10-4

0.2
 C2 = 201.93 x 10-6
After getting C2 ,substitute it in the equation
T = C2 + Ö c2 x D
2
=201.93 x 10-6 + Ö 201.93 x 10-6 x 90

=0.13491 cm
 t = 1.3491 mm.
But the standard thickness available for the roller clutch ring is 4 mm
 t = 4 mm.
Now,
R= Do – t
2
R = 110 - 4
2
= 55 – 4
R = 51 mm
Substituting R in equation (1)
a =( R - d ) cos µ - d
2 2
30.60 = 51 – 14 cos µ - 14
2 2
µ = 0.8545
= 31.2
Now;

Torque transmitting capacity of clutch

Mt = Ft x Z x R
Where Ft = F sin b
But b = µ = 31.29
2
Ft = 15.645
Substitute b in equ. (3)
Ft = f sin b
=3.014 x sin 15.645
ft = 0.8128 kgf
Mt = ft x Z x R
Mt = 0.8128 x 6 x 5.1
 Mt = 24.872 Kg.cm
=2.4878 x 103 N.mm
 As Torque designed to be transmitted is less than the transmitted torque

Hence our design is safe for roller clutch.
Check for bending failure

Mb1 = C1 x F X Rm
Where Rm = 1 ( D+t)
2
=1/2 (90 + 4)
R = 47 mm
Now
Mb1 = 0.089 x 4.7 x 3.014
Mb1 = 1.26 Kg cm
Now fbact = Mb = Mb
Z1 bt3/12
= 1.26 x 12
2 x (0.4)3

fbact = 118.122 Kgf

As fbact < fball
Hence clutch is safe in bending.
6.14 Design Of Spur Pinion & Rack
Stage 1: Drive as rack and pinion arangement

b = 10 m
Sult pinion = Sult rack = 600 N/mm2
Service factor (Cs) = 1.5
The rack and pinion arrangement is such that length of rack is110 mm where as pinion
has 10 teeth of which 3 are in simultaneous contact, hence the load on each tooth is
417N
Pt = 417 N.
Peff = 417 N (as Cv =1 due to low speed of operation)
Peff = 417 N --------(A)
Lewis Strength equation

WT = Sbym
Where ;
Y= 0.484 – 2.86
Z
 yp = 0.484 - 2.86 = 0.341

20
yg = 0.484 – 2.86 = 0.484
80
 Syp = 68.2
Syg = 89.6
WT = (Syp ) x b x m

=68.2 x 10m x m
WT= 682 m2----------(B)
Equation (A) & (B)
682 m2 = 417
m=0.78
selecting standard module = 1 mm
Thus the rack is of 1 mm module, 33 teeth where as pinion is of 1mm module
and 10 teeth.
Thus when the speed breaker goes down , the resultant stroke will rotate the
pinion through 3.3rotations approximately.
Stage 2
The second stage is an spur gear and pinion arrangement with 120 teeth on the spur
gear and 18 teeth on the spur pinion, the spur gear and pinion are of 1.5 module
Check for load carrying capacity of pair
WT WT = Sbym
Where ;
Y= 0.484 – 2.86
Z
 yp = 0.484 - 2.86 = 0.341

20
yg = 0.484 – 2.86 = 0.484
80
 Syp = 68.2
Syg = 89.6
WT = (Syp ) x b x m
=68.2 x 10m x m
WT= 682 m2----------(B)
Equation (A) & (B)

WT= 682 (1.5)2
 WT =1534N
As the load carrying capacity (1534N)> Actual load(1250N) the design is safe
The ratio of teeth on gear and pinion is 120/18=6.667, hence the speed of the
pinion shaft that carries the flywheel of 14inch effective diameter is 3.33 x 6.67
=22.211
CHAPTER – 7
MANUFACTURING PROCESS
SHEETS

7. MANUFACTURING PROCESS SHEET
PART NO : SBEG - 01 MATERIAL SPECIFICATION : EN 9

PART NAME : PUSH ROD
RAWMATERIAL SIZE: 30 X 560
QUANTITY :- 01 NO’S.
Sr Descriptio Tools Time in
. n of minutes
N Operation
o
Jigs & M/c Cuttin Measurin Setti M/ To
Fixture Tools g g ng c tal
Tools Instrume Time Ti Ti
nt me me
1. Clamp Three jaw Lathe - - 15 - 15
stock chuck
2. Facing B/S --”-- --”-- Facing Vernier 5 14 19
to total tool &
length center
550mm & drill
center
drilling
3. Clamp Center --”-- --”-- --”-- 25 25
stock support &
between carrier
center
4. Turning OD --”-- Turnin --”-- - 13 13
Ø 25 mm g tool
through out
length
5. Step --”-- --”-- - --”-- - 9 9
turning Ø
16 to
420mm
length
6. Threading --”-- --”-- Thread --”-- 25 27 52
M16 ing
threads tool

7. Milling key M/c vice Milling End --”-- 25 17 42

way m/c mill
6x3x125m
m 1no’s
8. Milling flat M/c --”-- --”-- --”-- -- 21 21
12.5 x 3 x
125
mm1No’s
MATERIAL SPECIFICATION : EN 9
PART NO : SBEG- 02
PART NAME : INT SHAFT
Sr. Description of Tools Time in minutes
Operation
No
Jigs & M/c Cutting Measuri Settin M/c To

Fixture Tools Tools ng g Time tal
Instrum Time Ti
ent me
1. Clamp stock Three jaw Lathe - - 15 - 15
chuck
2. Facing B/S to total --”-- --”-- Facing tool Vernier 5 14 19
length 130.2mm & & center
center drilling drill
3. Clamp stock Center --”-- --”-- --”-- 25 25
between center support
4. Turning OD Ø 30 --”-- Turning --”-- - 13 13
mm through out tool
length

5. Step turning Ø 25 --”-- --”-- - --”-- - 9 9

to 75mm length
6. Step turning Ø 24 --”-- --”-- Twist drill --”-- - 7 7
through 60 length
7. Step turning Ø 25 --”-- --”-- --”-- --”-- - 7 7

through 35 length
8. Step turning Ø 24 --”-- --”-- --”-- --”-- - 8 8

through 20 mm
length
9. Step turning OD Ø --”-- --”-- --”-- --”-- 7 7
19 mm through
15mm
10. Milling key way M/c vice Milling End mill --”-- 25 17 42
6x3x20mm 1no’s m/c
11. Drilling Ø12 M/c --”-- Twist drill --”-- 10 12 22

through 12mm
MATERIAL SPECIFICATION : EN24

PART NO : SBEG - 03
PART NAME : GUIDE BUSH
Sr. Description of Tools Time in minutes

Operation
No
Jigs & M/c Cutting Measuring Settin M/ Total

Fixture Tools Tools Instrument g c Time
Time Ti
me
1. Clamp stock 3 jaw Lathe - - 25 - 25
chuck
2. Drilling Ø 14 mm - --”-- Twist Vernier - 8 8

hole through drill
thickness
3. Boring Ø 16 mm - --”-- Boring --”-- 5 9 14

through thickness tool
4. Turning Ø40 - --”-- Turning --”-- 5 15 20

tool
Through length
5. Turning Ø35 - --”-- --”-- --”-- - 10 10
Through 5 mm length

6. Facing b/s to total - --”-- Facing --”-- - 20 20

tool
thickness
7. Slotting key way 6x3 3 jaw Slotting Slotting --”-- 10 26 36

mm chuck m/c tool

PART NO : SBEG - 04
PART NAME : GUIDE BUSH_2
Sr Description Tools Time in minutes

. of Operation
N
o

Fixture Tools Tools ng g Tim tal
Instrum Time e Ti
ent m
e
chuck
2. Drilling Ø 14 - --”-- Twist drill Vernier - 8 8

mm hole
through
thickness
3. Boring Ø 16 - --”-- Boring --”-- 5 9 14

mm through tool

thickness

tool
Through
length
5. Turning Ø32 - --”-- --”-- --”-- - 10 10
Through 37
mm length
6. Turning Ø26 - --”-- --”-- --”-- - 10 10
Through 18
mm length
7. Facing b/s to - --”-- Facing --”-- - 20 20

total tool
thickness

PART NO : SBEG - 05
PART NAME : SPRING BUSH
Sr Description of Tools Time in minutes

. Operation
N
o

Fixture Tools Tools ng g Tim tal
Instrum Time e Ti
ent m
e


chuck
2. Drilling Ø 14 - --”-- Twist Vernier - 8 8

mm hole drill
through
thickness
3. Boring Ø 16 - --”-- Boring --”-- 5 9 14

mm through tool
thickness

tool
Through length
5. Turning Ø26 - --”-- --”-- --”-- - 10 10
Through 18
mm length
6. Facing b/s to - --”-- Facing --”-- - 20 20

total tool
thickness
MATERIAL SPECIFICATION : EN 9
PART NO : SBEG - 07
RAWMATERIAL SIZE: 75X75X60
PART NAME : BEARING HOUSING
Sr Description Tools Time in minutes

. of
Operation
N
o
Jigs & M/c Cuttin Meas Setti M/c Tot

Fixture g uring ng al
Instr

Tools Tools ume Time Tim Ti

nt e me
1. Clamp stock M/C Vice Milling - - 15 - 15
2. Facing All --”-- --”-- Facing Verni 5 14 19

Sides Sq. to cutter er
total length
64x64x50
mm
3. Clamp stock 4 jaw chuck Lathe - - 25 25

on lathe
4. Drilling Ø 25 --”-- --”-- Twist Verni 15 10 25

through drill er
thickness
5. Boring Ø --”-- --”-- Boring Verni 15 10 25

46through tool er
thickness
6. Counter --”-- --”-- Boring Verni 15 10 25

Boring Ø 52 tool er
through
15thickness
7. Counter --”-- --”-- Boring Verni 15 10 25

Boring Ø 52 tool er
through
15thickness

CHAPTER – 8
ADVANTAGES
8. ADVANTAGES
1) Construction is easy and simple.

2) Easy in operation
3) No power supply for input.

4) No fuel required – Non-conventional source of energy.

CHAPTER – 9
DISADVANTAGES
9. DISADVANTAGES:
1) Initial cost of the setup is high

2) Energy losses in conversion
3) For more o/p, floor space area will be required more.

CHAPTER – 10
FUTURE COPE

FUTURE SCOPE
1) If the size of the whole set up is increased then the ouput will be also increased
2) Continuous motion of the pendulum may be done by providing sensors or
magnets

CHAPTER – 11
CONCLUSION
11. CONCLUSION

Here we conclude that two stage oscillator generate electricity with minimum
input and cost. Main objective of project is demonstrate and prove that the Kinetic
energy recovered by above pendulum system. This is done using on electric lamp the
quantification at energy required can be done using millimeter to measure current and
voltage, output from dynamo.
This can be done at different input condition i.e. by varying input motor speed
there by the energy recovered at various vehicle speeds can be determined.

CHAPTER – 12
REFEERENCE

12. REFERENCE
1. Tool design – by TATAMec-Gra Hill
2. Machine design-by R.S. Khurmi
3. Theory of machine- by Khurmi Gupta.
4. Work shop technology by -Hajra Chaudhary.
5. Industrial machine data book.
6. AutoCAD 2000i to 2004– By Autodesk –USA

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Electro Generator By Two-Stage Mechanical Oscillator

P.C. POLY, MECHANICAL DEPT. 1

1. NEED FOR PROJECT

1.1 Total Energy

P.C. POLY, MECHANICAL DEPT. 2

 Coal Fired Steam Plants

 Oil/Natural Gas Fired Steam Plants

P.C. POLY, MECHANICAL DEPT. 3

1.2 The Need for Alternative Energy

 Basic concept of alternative energy sources relates to issues of sustainability,

 Basic Barrier to all forms of alternative energy lies in initial costs!

 Currently we have no significant production line alternative energy source

P.C. POLY, MECHANICAL DEPT. 4

P.C. POLY, MECHANICAL DEPT. 5

The second component of the machine is a weighted pendulum. One of the

The combining of these two, separate mechanical oscillators into a single

P.C. POLY, MECHANICAL DEPT. 6

As with many of these types of motors and mechanisms, trying to understand

Electro-generator …Built –Up

P.C. POLY, MECHANICAL DEPT. 7

P.C. POLY, MECHANICAL DEPT. 8

Fig 2.1 Working Diagram of Project

P.C. POLY, MECHANICAL DEPT. 9

BLOCK DIAGRAM OF PROJECT &

P.C. POLY, MECHANICAL DEPT. 10

3.1 Block Diagram of Project

Fig 3.1 Block Diagram of Project

P.C. POLY, MECHANICAL DEPT. 11

3.2 Description of Block Diagram

The oscillation of the pendulum is given to the Two stage mechanical

P.C. POLY, MECHANICAL DEPT. 12

P.C. POLY, MECHANICAL DEPT. 13

SRNO PART DESCRIPTION QTY MATERIAL TOTAL

4.1 Estimate of Project (Approximate)

1. Raw material cost = 2800/-

P.C. POLY, MECHANICAL DEPT. 14

Total estimate of project =18260/

4.2 Facilities Available/Reqd.

Infrastructure And Machinery Required

4. Electrical arc welding

5. DRO milling machine

4.3 Man Power Required

P.C. POLY, MECHANICAL DEPT. 15

RESULTS & DISCUSSION

P.C. POLY, MECHANICAL DEPT. 16

5. RESULTS & DISCUSSION (PROPOSED WORK)

1. Design & development of Twin stage oscillator system.

P.C. POLY, MECHANICAL DEPT. 17

P.C. POLY, MECHANICAL DEPT. 18

6.1 Design Of See-Saw Power Generator

In our attempt to design a special purpose machine we have adopted a very a

6.2 In Mechanical design the component in two categories.

The various tolerance on work are specified in the manufacturing drawings

P.C. POLY, MECHANICAL DEPT. 19

6.3 System Design

6.3.1. System selection based on physical constraints:-

While selecting any m/c it must be checked whether it is going to be used in

6.3.2. Arrangement of various component

6.3.3. Components of system

As already stated system should be compact enough so that it can be

6.3.4. Man –m/c Interaction

The friendliness of m/c with the operation is an important criterion of design.

Following are some e.g. of this section

 Design of machine height