POWER GENERATION THROUGH HUMAN

MOTION
A PROJECT REPORT
submitted by

AKSHAY K CEM17ME012

AMALKRISHNA U S CEM17ME016

MUHAMMED ROSHAN N CEM17ME032

VINAYAK S R CEM17ME046

to

the APJ Abdul Kalam Technological University

in partial fulfillment of the requirements for the award of the Degree

of

Bachelor of Technology
in
Mechanical Engineering

Department of Mechanical Engineering

College of Engineering Muttathara

Thiruvananthapuram
JUNE 2021
 DECLARATION

I hereby declare that the project report ( “POWER GENERATION THROUGH

HUMAN MOTION”) , submitted for partial fulfillment of the requirements for
the award of degree of Bachelor of Technology of the APJ Abdul Kalam Techno-
logical University, Kerala is a bonafide work done by me under supervision of (
Mr. Sanalkumar B G ). This submission represents my ideas in my own words
and where ideas or words of others have been included, I have adequately and
accurately cited and referenced the original sources. I also declare that I have ad-
hered to ethics of academic honesty and integrity and have not misrepresented or
fabricated any data or idea or fact or source in my submission. I understand that
any violation of the above will be a cause for disciplinary action by the institute
and/or the University and can also evoke penal action from the sources which
have thus not been properly cited or from whom proper permission has not been
obtained. This report has not been previously formed the basis for the award of
any degree, diploma or similar title of any other University.

Signature

Place: TVM Akshay K

Date: Amalkrishna U S
Muhammed Roshan N
Vinayak S R
 DEPARTMENT OF MECHANICAL ENGINEERING
COLLEGE OF ENGINEERING MUTTATHARA
THIRUVANATHAPURAM

CERTIFICATE
This is to certify that the report entitled Power Generation Through
Human Motion submitted by Akshay K (CEM17ME012), Amalkr-
ishna U S (CEM17ME016), Muhammed Roshan N (CEM17ME032),
Vinayak S R (CEM17ME046) to the APJ Abdul Kalam Technological Uni-
versity in partial fulfillment of the requirements for the award of the Degree
of Bachelor of Technology in Mechanical Engineering is a bonafide record of the
project work carried out by him/her under my/our guidance and supervision.This
report in any form has not been submitted to any other University or Institute
for any purpose.

Internal Supervisor(s) External Supervisor(s)

Sanal Kumar B G (if any)
Assistant Professor
ME Department,CEM

HEAD OF THE DEPARTMENT

Coordinator(s)
Satheesh Kumar M
1. Name
Assistant Professor
2. Name
ME Department,CEM
 ACKNOWLEDGEMENT

I take this opportunity to express my deep sense of gratitude and sincere

thanks to all who helped me to complete the project successfully. I am deeply
indebted to my guide Mr. Sanalkumar B G, Asst Professor, Department of Me-
chanical Engineering for his excellent guidance, positive criticism and valuable
comments. I am greatly thankful to Mr. Satheesh Kumar M, Head of Mechanical
Engineering Department for his support and cooperation. Finally, we extend our
thanks to all our teachers and friends, without whose encouragement and support,
the project work would have never been a successful one. Finally, I thank my
parents and friends near and dear ones who directly and indirectly contributed
to the successful completion of my project.
 ABSTRACT

In this project we are generating electrical power as non-conventional method

by simply using our bodyweight. Non-conventional energy system is very essential
at this time to our nation. Non-conventional energy using footstep needs no
fuel input power to generate the output of the electrical power. This project
uses simple drive mechanism such as rack and pinion assembly and chain drive
mechanism. Here the conversion of the force energy in to electrical energy takes
place. The control mechanism carries the rack pinion, D.C generator, battery and
inverter control. We have discussed the various applications and further extension
also. So this project is implemented for foot step and the power generation is very
high. The initial cost of this arrangement is high.

iv
 Contents

List of Figures viii

List of Tables ix

Abbreviations x

1 INTRODUCTION 1

2 LITERATURE REVIEW 2
2.0.1 Power Generation in Automobile Suspension System” by C.
Nithiyesh Kumar, K.Gowtham, M.Mani- kandan, P.Bharathkanna,
T. Manoj Kumar . . . . . . . . . . . . . . . . . . . . . . . 2
2.0.2 “Generation of Electrical Energy from Foot Step Using Rack
and Pinion Mechanism” by Md.Azhar, Zitender Raj puro-
hit, Abdul Saif, Nalla Abhinay, P.Sai Chandu . . . . . . . 2

3 NEED FOR NON-CONVENTIONAL ENERGY 4

3.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Mild or low-carbon steel . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4 Manufacturing process used . . . . . . . . . . . . . . . . . . . . . 7
3.4.1 Cutting Machine . . . . . . . . . . . . . . . . . . . . . . . 7
3.4.2 Arc welding . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.4.3 Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.4.4 Lathe Turning . . . . . . . . . . . . . . . . . . . . . . . . . 10

v
4 FOOT STEP ARRANGEMENT 12
4.1 BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . 12

5 WORKING PRINCIPLE 13

6 DESIGN 15
6.1 DESIGN CONSIDERATION . . . . . . . . . . . . . . . . . . . . 15
6.2 DESIGN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 16
6.3 FACTORS TO BE CONSIDERED . . . . . . . . . . . . . . . . . 16
6.4 AESTHETIC CONSIDERATIONS IN DESIGN . . . . . . . . . 18
6.5 ASPECTS OF AESTHETIC DESIGN . . . . . . . . . . . . . . . 18
6.6 ERGONOMICS CONSIDERATIONS IN DESIGN . . . . . . . . . 19
6.7 MANUFACTURING CONSIDERATIONS IN DESIGN . . . . . . 19
6.8 STANDARDIZATION . . . . . . . . . . . . . . . . . . . . . . . . 20
6.8.1 Objectives of standardization . . . . . . . . . . . . . . . . 20
6.9 MECHANICAL PROPERTIES OF MATERIALS . . . . . . . . . 20

7 PART SPECIFICATION 22
7.1 SPECIFICATION OF PINION . . . . . . . . . . . . . . . . . . . 22
7.2 SPECIFICATION OF RACK . . . . . . . . . . . . . . . . . . . . 23
7.3 SPECIFICATION OF PLATES . . . . . . . . . . . . . . . . . . . 23
7.4 SHAFT DIMENSION . . . . . . . . . . . . . . . . . . . . . . . . 24
7.5 SUPPORTING PADDLE . . . . . . . . . . . . . . . . . . . . . . 24
7.6 DIMENSION OF ROD SUPPORTING FOR TOP PLATE . . . . 25
7.7 SPECIFICATION OF SPRING . . . . . . . . . . . . . . . . . . . 25

8 FABRICATION PROCESSES USED 26

8.1 LASER BEAM MACHINING (LBM) . . . . . . . . . . . . . . . . 26
8.1.1 Advantages of LBM . . . . . . . . . . . . . . . . . . . . . . 28
8.2 LATHE MACHINE OPERATIONS . . . . . . . . . . . . . . . . . 28
8.2.1 Facing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8.2.2 Turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8.3 DRILLING OPERATION . . . . . . . . . . . . . . . . . . . . . . 30
8.4 REAMING OPERATION . . . . . . . . . . . . . . . . . . . . . . 31

vi
 8.5 BORING OPERATION . . . . . . . . . . . . . . . . . . . . . . . 32
8.6 KNURLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8.7 Thread cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

9 RESULT & DISCUSSION 35

9.1 OUTPUT POWER CALCULATION . . . . . . . . . . . . . . . . 35

10 CONCLUSION 38
10.1 PRESENT CONFLICT . . . . . . . . . . . . . . . . . . . . . . . 38
10.2 FUTURE SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . 39

vii
 List of Figures

3.1 Cutting machine . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.2 Schematic diagram of arc welding . . . . . . . . . . . . . . . . . . 8
3.3 Drilling process . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.4 Lathe turning process . . . . . . . . . . . . . . . . . . . . . . . . 10

5.1 Basic design of Foot Step power generator . . . . . . . . . . . . . 14

7.1 Design of pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

7.2 Design of rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.3 Design of shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7.4 Design of supporting paddle . . . . . . . . . . . . . . . . . . . . . 24
7.5 Design of spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

8.1 Schematic diagram of LBM process . . . . . . . . . . . . . . . . . 26

8.2 Schematic diagram of facing process . . . . . . . . . . . . . . . . . 28
8.3 Schematic diagram of straight turning process . . . . . . . . . . . 29
8.4 Schematic diagram of step turning process . . . . . . . . . . . . . 29
8.5 Schematic diagram of eccentric turning process . . . . . . . . . . . 30
8.6 Schematic diagram of drilling operation . . . . . . . . . . . . . . . 31
8.7 Schematic diagram of reaming operation . . . . . . . . . . . . . . 31
8.8 Schematic diagram of boring operation . . . . . . . . . . . . . . . 32
8.9 Schematic diagram of knurling operation . . . . . . . . . . . . . . 33

9.1 Mass vs Power generated Graph . . . . . . . . . . . . . . . . . . . 37

viii
 List of Tables

9.1 Difference between theoretical and experimental results . . . . . . 36

ix
 ABBREVIATIONS

LBM : Laser Beam Machining

ME : Mechanical Engineering

x
 CHAPTER 1

INTRODUCTION

This project was motivated by the need for a device that would generate elec-
tricity from human motion, especially footsteps. Electricity is a very important
resource in people daily life. There are numerous sources from which are able to
generate electrical energy. The major sources of energy include but are not limited
to coal, natural gas, petroleum, and nuclear energy. Most of these sources have
adverse effects on the environmental inclusion such as air pollution; for example,
from coal energy generation plants which then cumulatively leads to effects such
as increase in rates of global warming.
This project seeks to establish an environmentally friendly way of generating
electric power from human motion. Such a system could be highly effective for
installation in places that expect frequent mobility of a large population such
as in educational institutions like universities and subway station entrances and
platforms.

1
 CHAPTER 2

LITERATURE REVIEW

2.0.1 Power Generation in Automobile Suspension Sys-

tem” by C. Nithiyesh Kumar, K.Gowtham, M.Mani-
kandan, P.Bharathkanna, T. Manoj Kumar
In this research paper author studied three methods of foot step power gen-
eration namely piezoelectric method, rack and pinion method and fuel piston
method comparatively and found that the rack and pinion mechanism is more
efficient with moderate cost of operation and maintenance

2.0.2 “Generation of Electrical Energy from Foot Step

Using Rack and Pinion Mechanism” by Md.Azhar,
Zitender Raj purohit, Abdul Saif, Nalla Abhinay,
P.Sai Chandu
In this research paper authors used regulated 5V power, 500mA power sup-
ply. Bridge type full wave rectifier is used to rectify the ac output of secondary
of 230/12V step down transformer. A rack and pinion is a type of linear actuator
including a pair of gears which convert rotational motion into linear motion. The
“pinion” engages teeth on the rack. In this paper, since the power generation
using foot step get its energy requirements from Non-renewable source of energy.
There is no need of power from external sources (mains) and there is less pollution

2
in this source of energy. It is very useful to the places like all roads and as well
as all kind of foot step which is used to generate the non-conventional energy like
electricity.

Department of ME 3 College Of Engineering Muttathara

 CHAPTER 3

NEED FOR NON-CONVENTIONAL

ENERGY

3.1 INTRODUCTION

Fuel deposit in the world will soon deplete by the end of 2025, Fuel scarcity
will be maximum. Country like India may not have the chance to use petroleum
products. Keeping this dangerous situation in mind we tried to make use of non-
pollutant natural resource of petrol energy.
The creation of new source of perennial, environmentally acceptable, low cost
electrical energy as a replacement for energy from rapidly depleting resources of
fossil fuels is the fundamental need for the survival of mankind. We have only
about 25 years of oil reserves and 75 – 100 years of coal reserves. Resort to mea-
sure beginning of coal in thermal electric stations to serve the population would
result in global elemental change in leading to worldwide drought and desertifi-
cation.
The use of nuclear electric-stations are limited to certain sectors.The solar,wind,rain,water
based power generations solely depend on the source factors which are not avail-
able everywhere and every time constantly.It is not possible to consider such sys-
tems for meeting continuous uninterrupted concentrated base load electric power
requirements.Energy plays an important role in the material, social and cultural
life of man kind. The energy needs are increasing day by day. This is the re-
sult of population growth and increase in the standard of living which is directly
proportional to energy consumption.

4
 For a number of these non-conventional energy sources, the weather, atmo-
spheric conditions and the environment have to cooperate for harnessing their
energy. Wind might be in short supply for wind turbines, or cloud cover might
interfere with solar energy collection. Geothermal plants have been known to de-
plete their energy source, sometimes unpredictably. This inconsistency and low
reliability can be costly, especially when the goal is to convert an energy source
into electricity for power distribution.
When the supply is inconsistent and unreliable, large quantities of power might
not be generated from non-conventional energy sources. That is problematic if
a country wants to depend on the energy source to meet the demands of pow-
ering an entire nation. The inconsistency, unreliability and unpredictability of
non-conventional energy sectors that are still in their infancy lead to debate on
whether the sectors are feasibly sustainable for the long term.
Pollution is a major ecological issue when it comes to non-conventional energy
sources. Wind turbine farms create noise pollution. Nuclear reactors create toxic
wastes that are harmful to living things, thus making storage, transport and dis-
posal a serious challenge. Geothermal plants have been associated with toxic
emissions such as sulfur dioxide, silica and heavy metal deposits of mercury, ar-
senic and boron.
Harmful risks from certain non-conventional energy sources are a reality. Wind
energy farms are notorious for harming species of birds, bats and insects with
windmill blades. Certain solar energy farms create intense hot zones in the atmo-
sphere from the amount of heat bouncing off their reflective surfaces. These hot
zones have harmed, blinded and killed passing birds and insects. The construction
of facilities to take advantage of ocean energy can destabilize marine ecosystems,
adversely affecting both nesting grounds and hunting grounds, threatening the
future of entire species.
Starting a farm or plant that leverages solar, wind, algae, geothermal, nuclear,
hydro-power and ocean avenues requires hefty funding and investments. Acquir-
ing the real estate to place the windmills, solar panels, algae farm, geothermal
facility, nuclear plant, hydro-power dam and ocean center requires sizable up-
front capital outlays to fund, build, maintain and implement the endeavors prop-
erly with infrastructure and technologies that are up to code standards. The

Department of ME 5 College Of Engineering Muttathara

large-scale production, maintenance and harvesting of algae can translate into
exorbitant expenditures.

3.2 Mild or low-carbon steel

Mild steel (iron containing a small percentage of carbon, strong and tough
but not readily tempered), also known as plain-carbon steel and low-carbon steel,
is now the most common form of steel because its price is relatively low while
it provides material properties that are acceptable for many applications. Mild
steel contains approximately 0.05–0.25% carbon, making it malleable and ductile.
Mild steel has a relatively low tensile strength, but it is cheap and easy to form;
surface hardness can be increased through carbonizing.
In applications where large cross-sections are used, to minimize deflection and
failure by yield is not a risk,so low-carbon steels are the best choice. For example
as structural steel. The density of mild steel is approximately 7.85 g/cm3 (7850
kg/m3 or 0.284 lb/in3) and the Young’s modulus is 200 GPa (29,000 ksi).
Low-carbon steels suffer from yield-point run out, where the material has two
yield points. The first yield point (or upper yield point) is higher than the second
and the yield drops dramatically after the upper yield point. If a low-carbon steel
is only stressed to some point between the upper and lower yield point then the
surface develop Lüder bands. Low-carbon steels contain less carbon than other
steels and are easier to cold-form, making them easier to handle.

3.3 Objectives
To design and develop the model of power generation. Also fabricate the
model which will work on the systems for required application. In this project we
are converting Mechanical energy into Electrical energy. We are trying to utilize
the wasted energy in a useful way. By using Rack and Pinion arrangement we are
converting to and fro motion of the steps into rotational motion of the dynamo.

Department of ME 6 College Of Engineering Muttathara

3.4 Manufacturing process used

3.4.1 Cutting Machine

Figure 3.1: Cutting machine

A cutting tool or cutter is any tool that is used to remove some material from
the work piece by means of shear deformation. Cutting may be accomplished by
single-point or multi-point tools. Single-point tools are used in turning, shaping,
planing and similar operations, and remove material by means of one cutting
edge. Milling and drilling tools are often multi-point tools. It is a body having
teeth or cutting edges on it. Grinding tools are also multi-point tools. Each grain
of abrasive functions as a microscopic single-point cutting edge (although of high
negative rake angle), and shears a tiny chip.
Cutting tool materials must be harder than the material which is to be cut, and
the tool must be able to withstand the heat and force generated in the metal-
cutting process. Also, the tool must have a specific geometry, with clearance
angles designed so that the cutting edge can contact the work-piece without the
rest of the tool dragging on the work-piece surface. The angle of the cutting face
is also important, as is the flute width, number of flutes or teeth, and margin size.
In order to have a long working life, all of the above must be optimized, plus the
speeds and feeds at which the tool is run.

Department of ME 7 College Of Engineering Muttathara

3.4.2 Arc welding

Figure 3.2: Schematic diagram of arc welding

Arc welding is a process that is used to join metal to metal by using electricity
to create enough heat to melt metal, and the melted metals when cooled results
in binding of the metals. It is a type of welding that uses a welding power supply
to create an electric arc between an electrode and the base material to melt the
metals at the welding point. They can use either direct (DC) or alternating (AC)
current, and consumable or non-consumable electrodes. The welding region is
usually protected by some type of shielding gas, vapor, or slag. Arc welding
processes may be manual, semi-automatic, or fully automated.

Department of ME 8 College Of Engineering Muttathara

3.4.3 Drilling

Figure 3.3: Drilling process

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

Department of ME 9 College Of Engineering Muttathara

3.4.4 Lathe Turning

(a) Roughing, or rough (b) Parting aluminium (c) Finish turning

turning

Figure 3.4: Lathe turning process

Turning is a machining process in which a cutting tool, typically a non-rotary

tool bit, describes a helix tool path by moving more or less linearly while the
work-piece rotates. The tool’s axes of movement may be literally a straight line,
or they may be along some set of curves or angles, but they are essentially linear
(in the non mathematical sense). Usually the term ”turning” is reserved for the
generation of external surfaces by this cutting action, whereas this same essential
cutting action when applied to internal surfaces (that is, holes, of one kind or
another) is called ”boring”. Thus the phrase ”turning and boring” categorizes
the larger family of (essentially similar) processes known as lathing. The cutting
of faces on the work piece (that is, surfaces perpendicular to its rotating axis),
whether with a turning or boring tool, is called ”facing”, and may be lumped into
either category as a subset.
Turning can be done manually, in a traditional form of lathe, which frequently
requires continuous supervision by the operator, or by using an automated lathe
which does not. Today the most common type of such automation is computer
numerical control, better known as CNC. (CNC is also commonly used with many
other types of machining besides turning.)
When turning, a piece of relatively rigid material (such as wood, metal, plastic,
or stone) work piece is rotated and a cutting tool is traversed along 1, 2, or 3
axes of motion to produce precise diameters and depths. Turning can be either
on the outside of the cylinder or on the inside (also known as boring) to produce
tubular components to various geometries. Although now quite rare, early lathes

Department of ME 10 College Of Engineering Muttathara

could even be used to produce complex geometric figures, even the platonic solids;
although since the advent of CNC it has become unusual to use non-computerized
tool-path control for this purpose.
The turning processes are typically carried out on a lathe, considered to be the
oldest machine tools, and can be of four different types such as straight turning,
taper turning, profiling or external grooving. Those types of turning processes can
produce various shapes of materials such as straight, conical, curved, or grooved
work piece. In general, turning uses simple single-point cutting tools. Each
group of work piece materials has an optimum set of tools angles which have been
developed through the years. The bits of waste metal from turning operations are
known as chips (North America). In some areas they may be known as turnings.

Department of ME 11 College Of Engineering Muttathara

 CHAPTER 4

FOOT STEP ARRANGEMENT

The arrangement is made up of mild steel. The complete set up is fixed

inside this model. The two L-shapes frame is fixed in the above two ends of the
bottom frame. In between this L shaped window, the actual power generation
arrangement is constructed. The top frame fixed with the rack is the initial point
of the working cycle which provides to and fro motion.

4.1 BLOCK DIAGRAM

12
 CHAPTER 5

WORKING PRINCIPLE

The complete diagram of the arrangement is given below. L-shaped frame

holds the core mechanism which generates power.The pushing power is converted
into electrical energy by proper driving arrangement.

The rack pinion, spring arrangement is fixed between the supporting frames
and the top frames. The spring is used to return the pushed top frame back-to
the same position by releasing the load. The pinion shaft is connected to the
supporter as shown in fig. The second gear is coupled with the pinion shaft. This
gear is coupled to another gear vertically with the help of gear arrangement.

This first gear is used to transfer the rotation force to the second gear. The
second gear is rotating in the same direction for the forward and reverse rotational
movements of the first gear.

The second gear wheel is coupled to the generator shaft . The generator used
here, is permanent magnet D.C generator. The generated voltage is approximate
12 Volt D.C. This D.C voltage is stored to the Lead-acid 12 Volt battery. The
battery is connected to the inverter. This inverter is used to convert the 12 Volt
D.C to the 230 Volt A.C. This 230 Volt A.C voltage is used to activate the light,
fan and etc.

By increasing the capacity of battery and inverter circuit, the power rating
is increased. The complete arrangement is kept inside the floor level except the

13
pushing arrangement.

Figure 5.1: Basic design of Foot Step power generator

Department of ME 14 College Of Engineering Muttathara

 CHAPTER 6

DESIGN

6.1 DESIGN CONSIDERATION

Several structural design considerations should be taken into account for eco-
nomical and efficient manufacturing. Many of these apply to other joining meth-
ods, and all apply to both sub assemblies and the complete structure.

• The device should be suitable for local manufacturing capabilities.

• The attachment should employ low-cost materials and manufacturing meth-

ods.

• It should be accessible and affordable by low-income groups, and should

fulfill their basic need for mechanical power.

• It should be simple to manufacture, operate, maintain and repair.

• It should be as multi-purpose as possible, providing power for various for

small machines used in rural industry.

• It should employ locally available materials and skills. Standard steel pieces
such as steel plates, iron rods, angle iron, and flat stock that are locally
available should be used. Standard tools used in machine shop such as hack
saw, files, punches, taps dies; medium duty welder; drill press; small lathe
and milling machine should be adequate to fabricate the parts needed for
the project.

15
 • It should make use of used parts wherever possible.

• The device should adapt easily to as many different sectors as possible.

• The mechanism should be as efficient as possible, and should develop rela-

tively high r.p.m. for versatility of application.

• The device should be able to transmit power to a variety of machines.

• Excessive weight should be avoided, as durability is a prime consideration.

6.2 DESIGN PROCEDURE

1. Definition of problem

2. Synthesis

3. Analysis of forces

4. Selection of material

5. Determination of mode of failure

6. Selection of factor of safety

7. Determination of dimensions

8. Modification of dimensions

9. Preparation of drawings

10. Preparation of design report

6.3 FACTORS TO BE CONSIDERED

• Strength

• Rigidity

Department of ME 16 College Of Engineering Muttathara

 • Reliability

• Safety

• Cost

• Weight

• Ergonomics

• Aesthetics

• Manufacturing considerations

• Assembly considerations

• Conformance to standards

• Friction and wear

• Product Life

• Vibrations

• Thermal considerations

• Lubrication

• Maintenance

• Flexibility

• Size and shape

• Stiffness

• Corrosion

• Noise

• Environmental considerations

Department of ME 17 College Of Engineering Muttathara

6.4 AESTHETIC CONSIDERATIONS IN DE-
SIGN
• Appearance is an outward expression of quality of the product and is the
first communication of product with the user.

• Aesthetics is defined as the set of principles of appreciation of beauty. It

deals with the appearance of the product.

6.5 ASPECTS OF AESTHETIC DESIGN

• Form(shape)

• Symmetry and shape

• Color

• Continuity

• Variety

• Proportion

• Noise

• Contrast

• Impression and purpose

• Style

• Material and surface finish

• Tolerance

Department of ME 18 College Of Engineering Muttathara

6.6 ERGONOMICS CONSIDERATIONS IN DE-
SIGN
• Ergonomics is defined as the study of the man - machine - working environ-
ment relationship

• It aims at decreasing the physical and mental stresses to the user

• Communication between man (user) and machine

• Working environment

• Human anatomy and posture while using the machine

• Energy expenditure in hand and foot operations

6.7 MANUFACTURING CONSIDERATIONS

IN DESIGN
• Minimum total number of parts in a product

• Minimum variety of parts

• Use standard parts

• Use modular design

• Design parts to be multi-functional

• Design parts for multiple use

• Select least costly material

• Design parts for ease of manufacture

• Shape the parts for minimizing the operations

Department of ME 19 College Of Engineering Muttathara

6.8 STANDARDIZATION
It is the process of establishing the set of norms to which a specified set of
characteristics of a component or a product should conform.
Example:Standardizing the shaft consists of specifying the set of shaft diameters
and material.

6.8.1 Objectives of standardization

• To make the interchangeability of the components possible

• To make the mass production of components easier

6.9 MECHANICAL PROPERTIES OF MATE-

RIALS
• Strength

• Stiffness/Rigidity

• Elasticity

• Plasticity

• Ductility

• Brittleness

• Malleability

• Toughness

• Machinability

• Resilience

• Creep

Department of ME 20 College Of Engineering Muttathara

 • Fatigue

• Hardness

Department of ME 21 College Of Engineering Muttathara

 CHAPTER 7

PART SPECIFICATION

7.1 SPECIFICATION OF PINION

Figure 7.1: Design of pinion

• MATERIAL : Mild Steel

• OUTSIDE OF DIAMETER : 40mm

• CIRCULAR PITCH : 4mm

• TOOTH DEPTH : 2.5mm

• MODULE : 1.8

• PRESSURE ANGLE : 20

22
 • NO OF TOOTH : 24

7.2 SPECIFICATION OF RACK

Figure 7.2: Design of rack

• MATERIAL : Mild Steel

• RACK PITCH DISTANCE : 20mm

• RACK LENGTH : 145mm

• NO OF TOOTH : 30

• LINEAR PITCH : 7mm

7.3 SPECIFICATION OF PLATES

• BASE PLATE SIZE : 400mm * 250mm

• TOP PLATE SIZE : 400mm * 200mm

Department of ME 23 College Of Engineering Muttathara

7.4 SHAFT DIMENSION

Figure 7.3: Design of shaft

• SHAFT DIA : 12mm

• LENGTH : 220mm

7.5 SUPPORTING PADDLE

Figure 7.4: Design of supporting paddle

Department of ME 24 College Of Engineering Muttathara

 • LENGTH OF SUPPORTING PLATE : 300mm

• WIDTH OF SUPPORTING PLATE : 75mm

7.6 DIMENSION OF ROD SUPPORTING FOR

TOP PLATE
• OUTER DIAMETER OF ROD : 12mm

• LENGTH OF ROD : 300mm

7.7 SPECIFICATION OF SPRING

Figure 7.5: Design of spring

• OUTER DIAMETER : 19mm

• INNER DIAMETER : 15mm

• WIRE DIAMETER : 2mm

Department of ME 25 College Of Engineering Muttathara

 CHAPTER 8

FABRICATION PROCESSES USED

8.1 LASER BEAM MACHINING (LBM)

Lasers are used for many purposes. One way they are used is for cutting
metal plates. On mild steel, stainless steel, and aluminum plate, the laser cutting
process is highly accurate, yields excellent cut quality, has a very small kerf width
and small heat affect zone, and makes it possible to cut very intricate shapes and
small holes.
Most people already know that the word “LASER” is actually an acronym for
Light Amplification by Stimulated Emission of Radiation.

Figure 8.1: Schematic diagram of LBM process

26
 The laser beam is a column of very high intensity light, of a single wavelength,
or color. In the case of a typical CO2 laser, that wavelength is in the Infra-Red
part of the light spectrum, so it is invisible to the human eye. The beam is
only about 3/4 of an inch in diameter as it travels from the laser resonator,
which creates the beam, through the machine’s beam path. It may be bounced
in different directions by a number of mirrors, or “beam benders”, before it is
finally focused onto the plate. The focused laser beam goes through the bore of
a nozzle right before it hits the plate. Also flowing through that nozzle bore is a
compressed gas, such as Oxygen or Nitrogen.
Focusing the laser beam can be done by a special lens, or by a curved mirror, and
this takes place in the laser cutting head. The beam has to be precisely focused
so that the shape of the focus spot and the density of the energy in that spot are
perfectly round and consistent, and centered in the nozzle. By focusing the large
beam down to a single pinpoint, the heat density at that spot is extreme. Think
about using a magnifying glass to focus the sun’s rays onto a leaf, and how that
can start a fire. Now think about focusing 6 KW of energy into a single spot, and
you can imagine how hot that spot will get.
The high power density results in rapid heating, melting and partial or complete
vaporizing of the material. When cutting mild steel, the heat of the laser beam
is enough to start a typical “oxy-fuel” burning process, and the laser cutting gas
will be pure oxygen, just like an oxy-fuel torch. When cutting stainless steel or
aluminum, the laser beam simply melts the material, and high pressure nitrogen
is used to blow the molten metal out of the kerf.
On a CNC laser cutter, the laser cutting head is moved over the metal plate in
the shape of the desired part, thus cutting the part out of the plate. A capacitive
height control system maintains a very accurate distance between the end of the
nozzle and the plate that is being cut. This distance is important, because it
determines where the focal point is relative to the surface of the plate. Cut
quality can be affected by raising or lowering the focal point from just above the
surface of the plate, at the surface, or just below the surface.
There are many, many other parameters that affect cut quality as well, but when
all are controlled properly, laser cutting is a stable, reliable, and very accurate
cutting process.

Department of ME 27 College Of Engineering Muttathara

8.1.1 Advantages of LBM
• Tool wear and breakage are not encountered.

• Very small holes with large aspect ratio can be achieved.

• A wide variety of hard and difficult-to-machine materials can be tackled.

• Machining is extremely rapid and the setup times is economical.

• Holes can be located accurately by using an optical laser system for align-
ment.

• The operating cost is low.

8.2 LATHE MACHINE OPERATIONS

8.2.1 Facing
Facing is the operation of machining the ends of a piece of work to produce
flat surface square with the axis. The operation involves feeding the tool perpen-
dicular to the axis of rotation of the work.

Figure 8.2: Schematic diagram of facing process

Department of ME 28 College Of Engineering Muttathara

8.2.2 Turning
Turning in a lathe is to remove excess material from the workpiece to produce
a cylindrical surface of required shape and size.

• Straight turning : The work is turned straight when it is made to rotate

about the lathe axis and the tool is fed parallel to the lathe axis. The
straight turning produces a cylindrical surface by removing excess metal
from the workpiece.

Figure 8.3: Schematic diagram of straight turning process

• Step turning : Step turning is the process of turning different surfaces

having different diameters. The work is held between centres and the tool
is moved parallel to the axis of the lathe. It is also called shoulder turning.

Figure 8.4: Schematic diagram of step turning process

Department of ME 29 College Of Engineering Muttathara

 • Eccentric turning : If a cylindrical workpiece has two separate axes of
rotating, one being out of centre to the other, the workpiece is termed
as eccentric and turning of different surfaces of the workpiece is known
as eccentric turning. The distance between the axes is known as offset.
Eccentric turning may also be done on some special machines. If the offset
distance is more, the work is held by means of special centres. If the offset
between the centres is small, two sets of centres are marked on the faces
of the work. The work is held and rotated between each set of centres to
machine the eccentric surfaces.

Figure 8.5: Schematic diagram of eccentric turning process

• Taper turning : A taper may be defined as a uniform increase or decrease

in diameter of a piece of work measured along its length.

8.3 DRILLING OPERATION

It is the process of producing cylindrical hole in the workpiece. In this oper-
ation, Workpiece is held in a chuck or a suitable device and the drill is held in
the tailstock. During operation, the drill is fed by rotating the handwheel of the
tailstockin clockwise direction. First a shorter length is drilled by using a smaller
and shorter drill, followed by producing the required diameter with the help of
correct drill size.

Department of ME 30 College Of Engineering Muttathara

 Figure 8.6: Schematic diagram of drilling operation

8.4 REAMING OPERATION

It is a finishing operation because a very small amount of material is removed
during the operation. For performing reaming a multi-teeth tool is used, which is
called as reamer. During the operation, the workpiece is held in a chuck or face
plate and the reamer shank is fitted in a sleeve or inserted in the tapered hole of
the tailstock spindle.

Figure 8.7: Schematic diagram of reaming operation

Department of ME 31 College Of Engineering Muttathara

8.5 BORING OPERATION
It is an operation which is employed for machining internal surfaces, hence
also called as internal turning. Boring is done to enlarge the already drilled hole
and bring them to the exact required size. Generally, a single point cutting tool
is used for this purpose.

Figure 8.8: Schematic diagram of boring operation

8.6 KNURLING
Knurling is the process of embossing a diamond shaped pattern on the surface
of the workpiece. The knurling tool holder has one or two hardened steel rollers
with edges of required pattern. The tool holder is pressed against the rotating
work. The rollers emboss the required pattern. The tool holder is fed automat-
ically to the required length. Knurls are available in coarse, medium and fine
pitches. The patterns may be straight, inclined or diamond shaped.

Department of ME 32 College Of Engineering Muttathara

 Figure 8.9: Schematic diagram of knurling operation

8.7 Thread cutting

Thread cutting is one of the most important operations performed in a lathe.
The process of thread cutting is to produce a helical groove on a cylindrical surface
by feeding the tool longitudinally.

1. The job is revolved between centres or by a The longitudinal feed should be

equal to the pitch of the thread to be cut per revolution of the work piece.

2. The carriage should be moved longitudinally obtaining feed through the

leadscrew of the

3. A definite ratio between the longitudinal feed and rotation of the headstock
spindle should be found Suitable gears with required number of teeth should
be mounted on the spindle and the leadscrew.

4. A proper thread cutting tool is selected according to the shape of the It

is mounted on the toolpost with its cutting edge at the lathe axis and
perpendicular to the axis of the work.

5. The position of the tumbler gears are adjusted according to the type of the
thread (right hand or left hand).

6. Suitable spindle speed is selected and it is obtained through back

Department of ME 33 College Of Engineering Muttathara

 7. Half nut lever is engaged at the right point as indicated by the thread
chasing

8. Depth of cut is set suitably to allow the tool to make a light cut on the

9. When the cut is made for the required length, the half nut lever is The
carriage is brought back to its original position and the above procedure is
repeated until the required depth of the thread is achieved.

10. After the process of thread cutting is over, the thread is checked by suitable
gauges.

Department of ME 34 College Of Engineering Muttathara

 CHAPTER 9

RESULT & DISCUSSION

9.1 OUTPUT POWER CALCULATION

let us consider the object weight to be 80kg (approx)

Range of vertical movement = 12cm

W orkdone = F orce × Distance

Here,
Force = Weight of the body ×M ass of acceleration
F = 80kg × 9.81m/s2
F= 784.8 N
Distance traveled by the body = Height of the top part
= 12cm
= 0.12m
Output power = Work done/time
= 784.4×0.12/60
= 1.56 Watts
Watt = volt×current

Max generator output current is 250mA

Therefore,

35
 Watt = volt x 0.25
By this we get voltage = 1.56/0.25
=2.08 volts approx.

This may vary according to how fast the force is applied.

Now, let us calculate with the specs of motor

Output Voltage : 12V

Speed : 300RPM
Max. Load Current : 250mA
Total motor power = Vout × Iout
=12v ×0.25A
=6 Watt

However, this much power produced, it cannot be tapped fully. From

the above purpose we have select to generate electricity by permanent magnet
type D.C generator and store it by 12V lead-acid battery cell.

Mass (Kg) Theoretical power (W) Experimental Power (W)

15 - 19 0.0736 0.0603
20 - 24 0.0981 0.0801
25 - 29 0.1226 0.1011
30 - 34 0.1472 0.1390
35 - 39 0.1717 0.1504
40 - 44 0.1962 0.1830
45 - 49 0.2207 0.2012
50 - 54 0.2453 0.2301
55 - 59 0.2698 0.2900
Table 9.1: Difference between theoretical and experimental results

The differences between the theoretical and actual results for different ranges
of mass of individual are presented in table and graph. It is observed that the
generated power increased proportionally with the mass of an individual. In
general, the individual with body mass around 55 kg are the teenager or adults

Department of ME 36 College Of Engineering Muttathara

with age above 18 years old. These participants are normally stronger, hence the
actual power generated from experiments were higher than the theoretical results.
Furthermore, it was also observed that the spring with higher stiffness needs to
be installed to the mechanical footstep generator designed for adults to ensure it
has higher durability.

Figure 9.1: Mass vs Power generated Graph

Department of ME 37 College Of Engineering Muttathara

 CHAPTER 10

CONCLUSION

10.1 PRESENT CONFLICT

Footstep power generation system produces electricity by utilizing energy
which is wasted through walking. Mechanism like rack and pinion and piezo-
electric material are integrated to produce desired output. Cost of electricity
generation solely depends upon the initial cost, maintenance cost and life of sys-
tem. Maximum advantage of this system can be taken if installed in highly
population dense area.
Since in this project of power generation there is not any fuel input requirement
for the generation of electrical power. Thus, it can also be concluded that this
mode of power generation system is ecofriendly, i.e., no pollution is caused during
the generation of power using this type of model. Hence due to such advantages,
this system can be embedded at any of the public places like railway platforms,
busy foot-paths, malls etc.
Implementing this system, we can easily reduce our dependency on the conven-
tional sources of energy, thus can be considered beneficial from that point of
view.
It is able to extend this project by using same arrangement and construct in
the footsteps/speed breaker so that increase the power production rate by fixing
school and colleges, highways etc. Footstep power generation system produces
electricity by utilizing energy which is wasted through walking. Mechanism like
rack and pinion and piezo-electric material are integrated to produce desired
output. Cost of electricity generation solely depends upon the initial cost, main-

38
tenance cost and life of system. Maximum advantage of this system can be taken
if installed in highly dense area.

10.2 FUTURE SCOPE

The project work “Power generation by Human Motion” is designed and de-
veloped successfully, for the demonstration purpose a proto type module is con-
structed with lower ratings of devices, results are found to be satisfactory. As
it is a demo module it cannot be used for real applications, but the concept is
near to the real working system, to make it more realistic, higher rating power
generator with suitable gear mechanism is essential to produce more energy.
This concept falls under the subject of non-conventional energy resources, out
of the many alternative energy resources one dependable source is solar energy,
but it is quite costliest affair. Therefore alternative cheapest source is to generate
electricity from foot step. This technology proven here is the ultimate inexpensive
source of all known forms of energy. When it is implemented practically, depend-
ing up on the size traffic flow, each foot step may produce tens of kilowatts power
every day, this power can be utilized for many applications. If we are used this
project at very busy places then we produce efficient useful electricity for large
purposes. One important advantage of producing energy through this technology
is that it does not pollute the environment. Hence these arrangement can be
altered with new technology, there by all the street lights belongs to a particular
city can be energized.

Department of ME 39 College Of Engineering Muttathara

 Bibliography

[1] E.C Chang, Y.C Liu, Int. J . Smart Grid Clean Energy 7, 2018.

[2] J. Thakur, S. Rauner, B. Chakraborty Int. J. Smart Grid Clean Energy, 6,

3, 2017

[3] Y. Stefanov, K. Ivanov, P. Petrov

Int. J. Smart Grid Clean Energy, 6, 3, 2017

[4] J. Zhang, A. Daniela, Y. Fang, A. Desmonda, E. O. Antwi,

Int. J. Smart Grid Clean Energy, 7, 3, 2018.

[5] N. Modi, P. Shrivastava, R. Bhardwaj, U. Jaiswal Int. Res. J. Eng. Tech. 3,

5, 2018

[6] A. Muhammad, A. Ali, S. Bibi,

Ener. Environ. Sus. Dev. 275, 2016

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