Retrofit Regenerative Shock Absorber Project

RETROFIT REGENERATIVE SHOCK ABSORBER
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
1
CONTENT:
Sr.
No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Title
Acknowledgement
Abstract
Concept Of The Project
Approach
Recognition Of Need
Regenerative Shock Absorber
Components
Design And Solid Modeling (Solid works)
Manufacturing
Cost Estimation
Conclusion
Page
No.
3
4
4
5
5
6
6
8
15
22
23
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.
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.
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%.
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
6
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.
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.
2. Bevel Gear:
3. Bevel Pinion:
4. Rack:
5. Pinion:
10
6. Dowel Pins:
7. Plungers:
8. Supporting Pillars:
11
9. Bearings:
10. Vertical Supporting Plates:
12
11. Horizontal Supporting Plate:
12. Motor:
13
ASSEMBLY
14
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:
15
i. Lathe Machine
ii. Universal Milling Machine
16
iii. Vertical Milling Machine
17
iv. Surface Grinding Machine
18
v. Cylindrical Grinding Machine
vi. Shapers
19
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.
20
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.
21
COST ESTIMATION
SR.
NO.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
DESCRIPTION
MAKE OR QUANTITY COST

BUY
(IN RS)
Gears, Rack and Pinion
Buy
5 nos.
1450
Shaft
Make
1 no.
300
Supporting Plunger
Buy
3 nos.
40
Bearings
Buy
3 nos.
100
Dowel Pins
Make
3 nos.
30
Acrylic Shaft
Make
1 no.
50
Vertical Pillars
Make
2 nos.
10
Plates
Make
3 nos.
300
Motor
Buy
1 no.
40
Electric Circuit
Buy
1 no.
15
Other Cost
800
Total Cost
3135
22
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.
23
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.
24

Retrofit Regenerative Shock Absorber Project

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