Project Report On Regenerative Shock Absorber

RETROFIT REGENERATIVE SHOCK ABSORBER

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A

PROJECT REPORT

ON


UNDER THE GUIDANCE OF

Prof. MANGESH MOHAN

SUBMITTED BY

ROOPESH M. PATEL

HEMANT KUMAR SINGH

AARADHYA G. BENDRE

HARSHAL B. TAMBE

IN THE PARTIAL FULFILLMENT OF THE REQUIREMENT

DIPLOMA IN PRODUCTION ENGINEERING

DEPARTMENT OF PRODUCTION ENGINEERING

AGNEL TECHNICAL COLLEGE

(POLYTECHNIC)

MUMBAI -50

2012 - 13


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CONTENT:

Sr.

No.

Title Page

No. 1. Acknowledgement 3

2. Abstract 4

3. Concept Of The Project 4

4. Approach 5

5. Recognition Of Need 5

6. Regenerative Shock Absorber 6

7. Components 6

8. Design And Solid Modeling (Solid works) 8

9. Manufacturing 15

10. Cost Estimation 22

11. Conclusion 23


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ACKNOWLEDGEMENT

Successful completion of any project is never on individual

effort, but team effort is needed for it. It is an immense pleasure

to express our sense of gratitude to all the people who have

extended their valuable help during the development of this

project.

We harbor a deep sense of oblige on to our guide Prof.

Mangesh Mohan, who has given ample ideas in the development

of the project and for the encouragement in the same. One of the

sweetest quality of sir which has really increased our respect

towards him is that he encourages all the new ideas. During the

course of project we cancel many project because we wanted to

do something best. But instead of scolding us, he always gave

new ideas and his own suggestion to that particular topic. And

today only because of his attitude we were able to bring our ever

rising developing into reality.

We have great pleasure in expressing our gratitude to our

principal N. M. Joshi sir for giving us such good opportunity

where we can develop our thinking capacity and bring our

imagination into reality.

We wish to express us a special word of thanks to the entire

staff of production department and our friends who always gave

helping hand to us.


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ABSTRACT

A shock absorber is a device which absorbs shock which is

developed in automobiles. The energy required to damp these vibrations

is wasted in form of heat. Retrofit Regenerative shock absorbers fit with

the same arrangement and utilize this energy to increase the overall

efficiency of the system.

CONCEPT OF THE PROJECT

A Regenerative shock absorber consists of a rack and pinion

arrangement to convert irregular vibrations into useful electric energy.


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APPROACH TOWARDS THE PROJECT

The first step to be followed to proceed with the project was the

design process. We first of all designed all components for the assembly;

performed the project feasibility study. The study concluded that some of

the components were not easily available in the market or their

manufacturing was not that easy. Later on we designed the components

for manufacturing; i.e.; we designed the components that are easily

available and easy to manufacture.

NEED FOR REGENERATIVE SHOCK ABSORBERS:

Through detailed scientific study it is found that the transportation

counts for 70% of overall fuel consumption over three quarters of which

is for road vehicles. Vehicles exhaust causes more air pollution than

anything else. Considering only 10-16% of fuel energy is used to actually

drive vehicles - to overcome the resistance from road friction and air drag,

the improvement of the fuel efficiency is always an important issue.

Recently research also indicates that vehicle suspensions have substantial

influence on the fuel efficiency. Through modeling and road tests, Zuo

and Zhang estimated that 100-400 Watts of energy harvesting potential

exist in the suspension of a typical passenger vehicles traveling at 60 miles

per hours on the good and average roads, and more energy is available for

the trucks or on the rough roads.

When used instead of conventional shock absorbers regenerative

systems would be capable to increase the overall efficiency of the system

up to 10%.


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REGENERATIVE SHOCK ABSORBER

An innovative design of regenerative shock absorbers is proposed in

this paper, with the advantage of significantly improving the energy

harvesting efficiency and reducing the impact forces caused by

oscillation. The key component is a unique motion mechanism, which we

called “mechanical motion rectifier (MMR)”, to convert the oscillatory

vibration into unidirectional rotation of the generator. An implementation

of motion rectifier based harvester with high compactness is introduced

and prototyped. A dynamic model is created to analyze the general

properties of the motion rectifier by making analogy between mechanical

systems and electrical circuits.

COMPONENTS

A Regenerative shock absorber consists of:

1. A rack and pinion arrangement to convert irregular vibrations into

oscillatory motion. The rack and pinion arrangement drives two bevel

gears which convert the bi-directional motion of the pinion into

unidirectional motion of the bevel pinion. The bevel pinion is coupled

to the motor shaft which will then generate electricity.

2. Casing:

It consists of a round and a hollow casing. This casing holds and

supports all the parts in it, the whole mechanism is mounted in the


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Casing and provision is given for electrical circuits to be connected to

the motor.

3. Bevel Gear:

There are two bevel gears used in the mechanism. The larger or driving

bevel gear is mounted directly on the main shaft using dowel pins and

plunger attachments. The larger bevel gear drives the bevel pinion and

provides unidirectional motion.

4. Plunger attachments:

These are cylindrical bodies containing springs and provide oscillatory

movement. In our mechanism the plunger attachments are mounted

inside the shaft itself. These plungers provide support to the dowel pins.

5. Dowel Pins:

Dowel pins are mounted on the axial slots cut on the shaft. These dowel

pins rotate and slide in the slots with the help of plungers. These pins

serve the main purpose of clutching and overrunning of the bevel gears

mounted on the shaft.

6. Motor:

The motor is coupled with its axis perpendicular to the main shaft.

When the bevel pinion rotates in a unidirectional motion the shaft of

the motor rotates and this generates voltage on the other end of the

circuit connected to the motor.

7. Electrical circuit:

The electrical circuit is basically a rectifier circuit which converts

rotational motion into direct electrical current.


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DESIGN

1. Shaft:

The main shaft was designed to have axial slots up to

some distance and drilled at three positions to hold the

plunger within it.


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2. Bevel Gear:

3. Bevel Pinion:


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4. Rack:

5. Pinion:


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6. Dowel Pins:

7. Plungers:

8. Supporting Pillars:


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9. Bearings:

10. Vertical Supporting Plates:


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11. Horizontal Supporting Plate:

12. Motor:


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ASSEMBLY


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MANUFACTURING

Our workshop at Fr. Agnel Technical College.

Most of the parts except the gears were manufactured in the

workshop itself by using our design. In order to manufacture all

these components, we used following machines:


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i. Lathe Machine

ii. Universal Milling Machine


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iii. Vertical Milling Machine


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iv. Surface Grinding Machine


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v. Cylindrical Grinding Machine

vi. Shapers


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vii. Power Saw

Following list shows how we manufactured all the components:

1. Shaft:

The shaft was turned on lathes

The slots in it were milled on Universal Milling Machine.

The periphery of the shaft was ground on Cylindrical

Grinding Machine

2. Bevel Gears, Rack and Pinion:

All the these components were sub contracted to Patel

Brothers Co. Ltd., where they were manufactured on

hobbing machines

3. Horizontal and Vertical Plates:

These parts were cut from rectangular blanks and ground on

Surface Grinding Machine.

4. Bearings

Bearings were required for mounting the main shaft and the

coupling shaft.

We manufactured shafts with standard bearing size and

bearings with appropriate size were bought.


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5. Coupling Shaft

The coupling or the vertical shaft connected the bevel pinion

to the motor shaft.

For this purpose we manufactured an acrylic shaft on our

C.N.C. turning section in such a way that it press fit in the

internal diameter of the bevel pinion and external diameter

of the motor shaft.

6. Casing

The casing was made cutting P.V.C. pipes up to required

length.

7. Other parts :

All other parts listed below were available to us as

readymade standard parts:

a) Dowel pins.

b) Supporting plunger.

c) Bearing.

d) Motor.


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COST ESTIMATION

SR.

NO.

DESCRIPTION MAKE OR

BUY

QUANTITY COST

(IN RS)

1. Gears, Rack and Pinion Buy 5 nos. 1450

2. Shaft Make 1 no. 300

3. Supporting Plunger Buy 3 nos. 40

4. Bearings Buy 3 nos. 100

5. Dowel Pins Make 3 nos. 30

6. Acrylic Shaft Make 1 no. 50

7. Vertical Pillars Make 2 nos. 10

8. Plates Make 3 nos. 300

9. Motor Buy 1 no. 40

10. Electric Circuit Buy 1 no. 15

11. Other Cost - - 800

Total Cost 3135


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CONCLUSION

An innovative implementation of the regenerative shock

absorber is introduced with high compactness and

improved efficiency. The roller clutches are eliminated

using improved shaft design embedded in a bevel gear and

the function of “Unidirectional Motion” is achieved with

two bevel gears. In addition, the mechanical-electrical

system of the regenerative shock absorber is modeled with

a circuit-based method to analyze the dynamic properties

of the system. Finally the shock absorber is characterized

with bench tests. The “Shaft” based design achieved a

mechanical efficiency of over 60% and no obvious

backlash effect. The simulation and experiment results

indicate that advantage of new design is more important

with higher input frequency, and the efficiency is higher

correspondingly.


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SPECIAL THANKS

We would like to thank our whole workshop staff for their support

and coordination during the project.

1. Malcolm Sir

2. V. K. Desai Sir

3. Tilak Sir

4. Kamble Sir

5. Panchal Sir

6. Shyam Sir

And the supporting staff.

Documents

Project Report On Regenerative Shock Absorber