ABSTRACT
The ever-increasing need for electricity demands the investigation of novel and
sustainable techniques of power generation. This study looks at the possibility of a
rack and pinion system for power collecting. We describe the design and
construction of a system that uses a rack and pinion assembly to transform linear
motion into rotational motion. A generator converts this rotating motion into power.
The report describes the components employed, their capabilities, and the basic
operation of the power production process. It goes into more detail on the outcomes,
such as the quantity of power produced and the system's efficiency. Additionally,
any obstacles encountered during the project, as well as the solutions applied, will
be presented. Finally, the report concludes by proposing potential improvements for
future iterations of the system, aiming to enhance its efficiency and functionality.
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CHAPTER – 1
1.1 INTRODUCTION
The demand for reliable and sustainable power sources is being driven by the
increasing global dependency on energy. This study explores the possibility of
collecting power using a common mechanical part called a rack and pinion
mechanism.
Because of its versatility and capacity to transform rotational motion into linear
motion and vice versa, rack and pinion systems are frequently used in many different
applications. The goal of this study is to investigate the feasibility of applying this
conversion mechanism to produce power from linear movement.
We show the architecture and development of a system whose main constituent is a
rack and pinion mechanism. Then, using the proper mechanism, the linear motion
produced by the rack and pinion is transformed into rotational motion. This
rotational movement powers a generator, ultimately producing electricity.
This report lists all of the system's components and describes each one's unique
purpose. We will examine the whole system's operation and clarify how the rack and
pinion mechanism make it easier to generate power. The report will go into further
detail on the outcomes, such as the quantity of power generated and the overall
effectiveness of the system.
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There will also be a discussion of the difficulties faced throughout the project's
development and the solutions that were used. The research finishes by outlining
prospective upgrades for next generations of the system, with the goal of boosting
its effectiveness and expanding its capabilities in the field of energy collecting.
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CHAPTER - 2
2.1 COMPONENTS
1. Pinion (Gear)
2. Rack
3. Geared DC motor (Generator)
4. Springs
5. LED’s
2.1.1 Pinion (Gear)
Fig 2.1.1 PINION GEAR
The simplest and most prevalent kind of gear is a spur gear. It is a cylindrical
component with teeth that extend outward from the body. The gear's teeth are parallel
to its axis of rotation and straight.
Function:
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Conversion of Linear Motion: Highlight that the spur gear (pinion) plays a critical
role in converting linear motion from the rack into rotary motion. Explain how the
teeth of the pinion mesh with the teeth of the rack, causing the pinion to rotate as the
rack moves linearly.
Size and material
Three plastic spur gears were utilized in this project.
extra-large gear 70 mm
big gear 40 mm
30 mm
tiny gear
2.1.2 Rack
Fig 2.1.2 RACK
A rack gear, or simply a rack, is a stiff, straight bar with teeth cut along one flat
surface used in equipment. These teeth are made to mesh with a gear, usually a
pinion, which is a circular gear. The plastic rack was used in the project.
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Number of teeth present on the rack is 48 and length of the teeth is 22.5 CM.
2.1.3 DC Motor (Generator)
Fig 2.1.3 DC MOTOR
Principle: The shaft of a DC motor is normally rotated by electricity. However, the
fundamental idea of electromagnetic may be turned around. A DC motor really
produces electricity at the terminals, or wires, that are attached to the motor windings
when the shaft of the motor is spun. The maximum voltage generated by the DC
motor around 12-14 V. (at high RPM)
Geared Motor Advantage: This idea remains unchanged by the gearbox in a geared
DC motor. It simply modifies the relationship between the voltage produced and
the input's speed, which rotates the shaft.
2.1.4 Springs
Fig 2.1.4 SPRING
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Compression Springs: Designed to handle pushing forces, these are found in shock
absorbers, ballpoint pen mechanisms, and valves.
2.1.5 LEDS
Fig 2.1.5 LED
A light-emitting diode, or LED for short, is a semiconductor that, when an electric
current passes through it, creates light. Transforms electrical energy into light energy
as its function.
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2.2 WORKING PRINCIPLE
Fig 2.2.1 RACK AND PINION MECHANISM
The Rack and Pinion Electricity Generation System's Operating Principle With the
use of a rack and pinion system, this project transforms linear motion into rotational
motion, which in turn produces energy. The operational principle is broken down as
follows:
2.2.1 Input Force:
For the system to begin linear movement, there must be an external force source.
The design may have an impact on this force. As examples, consider:
Human Step: The linear motion can be produced by a human stepping on a platform
that is attached to the rack.
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Vehicle Weight: The linear force can be produced by the weight of a vehicle going
over a speed bump that has been particularly constructed with a rack and pinion
system.
2.2.2 Rack and pinion mechanism:
The system's main component is the rack and pinion assembly. The rack is a
straight bar with teeth machined along the full length. The pinion is a circular gear
that meshes with the rack's teeth.
When an external force delivers a linear push or pull on the rack, the teeth engage
with the teeth of the pinion gear. This causes the pinion gear to revolve along its
axis.
2.2.3 Rotary to Electricity Conversion:
The rotational action of the pinion gear is subsequently transmitted to a generator.
The type of generator utilized varies depending on the project's design and
intended output voltage.
Small DC Motor: A commonly available DC motor can be reversed to act as a
generator, converting mechanical rotation to electrical current.
The generator's shaft rotates, spinning the rotor inside the generator. This spinning
action generates a magnetic field that interacts with the coils of wire inside the
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generator. This interaction causes an electrical current in the coils, which generates
electricity.
2.2.4 Electrical Output:
The system's electricity can be measured with a voltmeter. The amount of power
produced is determined by numerous factors, including:
Force Applied: The stronger the force applied to the rack, the faster the pinion gear
rotates, resulting in more electricity generation.
Generator Efficiency: The efficiency of the generator in turning mechanical
rotation into electricity influences the final output.
System Friction: Friction between moving parts (rack, pinion, generator) can cause
energy loss and lower overall electricity production.
2.2.5 Bi-Directional Electricity Generation (special feature):
One of the distinctive features of this project is its ability to generate electricity
during both the compression and expansion strokes of the rack and pinion
mechanism. This stands in contrast to traditional setups that typically only generate
electricity during the compression phase.
• Bi-directional Generator: If the generator rotates clockwise, it generates
currents from the anode (positive charge) and the cathode (negative charge),
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and if it rotates anticlockwise, it creates current from the anode (negative
charge) and the cathode (positive charge).
• Circuit modification: From the generator output, LED L1 is connected
to the positive anode and negative cathode, while LED L2 is connected to
the positive cathode and negative anode. Just vice versa.
Benefits of Bi-Directional Operation
• Increased Electricity Output: By capturing electricity during both strokes, the
system has the potential to double the electricity generation compared to a one-way
system for the same amount of back-and-forth movement (assuming similar
efficiency in both directions).
• Efficiency in Movement-Based Applications: This feature is particularly
advantageous in scenarios where the source of movement (human steps, weight of
an object) inherently involves both compression and expansion phases. The system
can effectively harvest electricity throughout the entire movement cycle.
ENERGY CONVERSION DONE IN THE PROJECT
In this project the conversion of the energy i.e. which from the kinetic energy to
rotatory motion (potential energy). This rotatory motion is converted to electrical
energy through the DC generator(dynamo).
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CHAPTER – 3
3.1 TESTING
3.1.1 Functionality Testing:
Verify the smooth and consistent movement of the rack and pinion assembly under
various loads (up to the maximum capacity of 45kg).
Measure the voltage output generated at different force levels to understand the
system's performance.
Observe the LED response and ensure it accurately indicates the compression and
expansion strokes.
3.1.2 Stress Testing:
Gradually increase the applied force on the rack up to the maximum capacity (45kg)
and observe for any signs of weakness, deformation, or excessive wear in the
components.
Monitor the system's behavior under this maximum load, ensuring smooth operation
and no overheating of components.
3.1.3 Safety Testing:
Check for any potential pinch points or hazards where moving parts could cause
injury.
Ensure all electrical connections are secure and follow proper safety practices to
avoid shock circuits.
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3.1.4 Factor of safety:
1. Choose a design load:
The design load represents the force the system is intended to handle regularly and
should be lower than the maximum load capacity (45kg). This concept helps
incorporate a safety margin.
➢ Conservative Approach (Recommended):
If safety is a top priority, choose a design load significantly lower than 45kg.
Consider a value in the range of 30kg to 35kg.
2. Research Steel Yield Strength:
The yield strength is the maximum stress a material can withstand before permanent
deformation occurs. For steel racks, the yield strength typically falls within the range
of 200 MPa (Megapascals) to 300 MPa. In this project the project plastic rack is used
so yield strength typically, from the 30MPa to 45MPa.
3. Calculate FOS:
Factor of safety = yield strength of rack
Design load
FOS = 30
30*9.81
= 0.1019*100
FOS = 10.19
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3.2 RESULT
The specific results of your project will depend on the measurements that took during
testing. However, we can outline the general areas where present’s the results and
calculations:
3.2.1. Electricity Output (Voltage):
The voltage generated by the system at different applied forces is
min electricity generated is 1.85v and 0.15A
max electricity generated is 3v and 0.2A
3.2.2. EFFICIENCY
η = Electrical power (V*I) / mechanical power (F*D)
where,
V = voltage generated during the power stoke and expansion stoke. (V)
I = Amp generated during the power stoke and expansion stoke. (A)
F = Force applied to rack. (Kg)
D = Distance move by the rack (M)
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η= V*I
F*D
η= 3*0.2 = 0.6 = 0.6116
10*9.81*0.01 0.981
η= 0.6116*100
η = 61.16%
Finally, the efficiency of the rack and pinion mechanism is the 61.16%.
The frictional losses, generator losses, other losses is around 38.84%.
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CHAPTER – 4
4.1 CONCLUSION
This project successfully demonstrated the feasibility of using a rack and pinion
mechanism for electricity generation. The incorporation of LED stroke indication
adds a unique feature to the system. The project highlights the potential for small-
scale sustainable power generation through innovative approaches. Future
improvements can further enhance the system's efficiency and functionality, paving
the way for wider applications of this technology.
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4.2 BIBLIOGRAPHY
1. Rack and Pinion Mechanism:
Mechanism and Machine Theory by J.G. Norton
https://en.wikipedia.org/wiki/Rack_and_pinion
National Geographic. Science & Innovation.
https://support.nationalgeographic.org/s/article/More-Information-About-National-Geographic-
Partners-LLC
Norton, R. L. (2009). Mechanism and Machine Theory. McGraw-Hill Education.
2. Electricity Generation and Generators:
HowStuffWorks - How Generators Work
https://www.youtube.com/watch?v=KDXeWqMQJ0E
https://help.nationalgeographic.com/
3. Small-Scale Electricity Generation:
Department of Energy - Energy Efficiency & Renewable Energy
https://www.energy.gov/eere/office-energy-efficiency-renewable-energy
4. ScienceDirect - Energy for Sustainable Development
https://www.sciencedirect.com/journal/energy-for-sustainable-development
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