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DESIGN AND FABRICATION OF

LEVANT SHOCK ENERGY

APROJECTREPORT

Submitted by

T.SATHISH KUMAR (41908114313)

K.VENKAT BALAJI (41908114015)

M.C.SAREN JEYAKUMAR (41908114035)

ABHIMENYU (41908114002)

Inpartial fulfillment for the award of the degree

Of

BACHELOR OF ENGINEERING

In

MECHANICAL ENGINEERING

SSR R II SSAAII R R AA MM EE NN GG II NN EE EE R R II NN GG CC OO LL LL EE GG EE ,, CC HH EE NN NN AA II -- 660000 004444

AA NN NN AA UU NN II VV EE R R SSII TT YY :: CC HH EE NN NN AA II -- 660000 002255

AA PP R R II LL 22001111

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AANNNN AA UUNNIIVVEER R SSIITTYY:: CCHHEENNNNAAII 660000 002255

BB OO NN AA FF II DD EE CC EE R R TT II FF II CC AA TT EE

Certified that this project report on DD EE SSII GG NN AA NN DD FF AA BB R R II CC AA TT II OO NN OO FF LL EE VV AA NN TT SSHH OO CC K K EE NN EE R R GG YY iiss tthhee BBoonnaaf f iiddee wwoor r k k oof f

T.SATHISH KUMAR (41908114313)

K.VENKAT BALAJI (41908114015)

M.C.SAREN JEYAKUMAR (41908114035)

ABHIMENYU (41908114002)

Who carried out the project work under my supervision.

SSII GG NN AA TT UU R R EE SSII GG NN AATT UU R R EE

Dr.A.RAJENDRAPRASADMr.PANDIARAJAN DDEEAANN-- R R &&DD LECTURER

HH EE AADD OO FF TT HH EE DDEE PP AAR R TT MM EE NN TT SSUU PP EE R R VV II SSOO R R Mechanical Engineering Mechanical Engineering

Sri Sairam Engineering College Sri Sairam Engineering CollegeSai Leo Nagar, West Tambaram, Sai Leo Nagar,WestTambaram

Chennai -600 044.Chennai 600 004.

Submitted for viva-voce held on

II nn tt eerr nn aa ll EE xxaa mm iinn eerr EE xxtt eerr nn aa ll EE xxaa mm iinn eerr

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AA CC K K NN OO WW LL EE DD GG EE MM EE NN TT

We express our sincere thanks to our chairman Thiru. MJF.Ln.LEO MUTHU ,

Our director Prof.V.R.RAJAMANICKAM ,our CEO MM rr ..SSAAII PP R R AAK K AASSHH LL EE OO

MM UUTT HH UUSRI SAI RAM ENGINEERING COLLEGE , for their kind attention and

valuable suggestions given to me throughout the course.

We are deeply indebted to our Principal Prof.Dr.C.V.JAYAKUMAR , for being

a source of inspiration throughout my study in this College.

We thank our Head of the Department Dr.A.RAJENDRA PRASAD , Project

Co-coordinator Mr.ASHOK GG AANNDD HH II f f oor r tthheeiir r ssuuppppoor r tt and our staffs for their

guidance and encouragement at each and every stage of our project work and also

guiding us properly throughout the reviews.

With profound respect, we express our deep sense of gratitude and sincere

thanks to Mr.PONRAJ (R&D ALFO ELECTRICALS) and Mr.JAGANNATHAN (HR-

ERIEZ MAGNETICS INDIA PVT.LIMITED) , for his valuable guidance and

suggestions and support.

Finally our hearty respect and gratitude towards Mr.PANDIARAJAN who has

been our internal guide in making this project successful and being with us

throughout the progress of the project.

We take this opportunity to extend our thanks to all persons who have

directly or indirectly helped us in the progress of the project.

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ABSTRACT

Shock absorbers arethe mechanical device that absorbs or dampens

shock impulse and dissipate kinetic energy. Shock absorbers are a significant

part of automobile and motorcycle suspensions. The shock absorbers duty is

to absorb or dissipate energy.

Whenever the vehicle moves in ups and downs, the piston in the

shock absorber being the heart of the device also moves up and down which

is said that the shock absorber has absorbed the vibration and the passengers

feel the comfort during the ride.

The main idea of the project is to make use of this to and fro motion

of the piston and convert it into some useful form of energy other than

wasting it without disturbing the damping facility that is been provided in

the shock absorbers .

The useful form of energy that is been obtained from the motion of

the piston is ELECTRICAL ENERGY by using the principle of Faradays

Law of Electromagnetic Induction (i.e.by using the magnet and copper

coil as the major elements).

The power that is generated in this mechanism is further converted

into DC by using a bridge rectifier and makes use this power supply for

charging the battery of the mobile.

Hence the concept of the project is deeply explained below with also

their limitations involved in using it.

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CONTENTS

CHAPTER TITLE PAGE NO

ACKNOWLEDGEMENT iABSTRACT iiLIST OF TABLES iiiLIST OF FIGURES iv

1 INTRODUCTION

2 ELECTRICAL CONCEPTS AND LAWS

2.1 SI units based upon the magnetic propertiesOf electric currents.

2.2 Joules law

2.3 Ohms law2.4 Properties of the magnet2.5 Coulomb s law

2.6 Electrical field2.7 Electrical intensity

2.8 Electrical flux

2.9 Law of electromagnetic induction2.10 Faraday s law of electromagnetic induction

2.11 Lenz s law of electromagnetic induction

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FARADAY LAW

LENZS LAW

MAGNET AND COIL

3 MECHANICAL CONCEPTS

3.1 Shock absorbers

3.2 Types of shock absorbers3.3 Purpose of shock absorbers

3.4 Suspension system3.5 Components of suspension system3.6 Functions of suspension system3.7 Principles of suspension system

3.8 Basic suspension movements3.9 Types of suspension springs

3.10 Types of suspension system

4. COMPARISON SPECIFIC CHART FOR

VARIOUS INDUSTRIAL PLASTICS

5. DESIGN AND FABRICATION

5.1Design of shock absorber

5.2Working principle

5.3Modifications done

5.4Experiments conducted

5.5Further progress on the project

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6 COST ESTIMATION

7 CONCLUSION

8 BIBLIOGRAPHY

LIST OF TABLES

1. SI electromagnetism units

2. Comparison chart of various industrial plastics

LIST OF FIGURES

1. Faradays law2. Lenzs law3. Magnet and coil4. Shock absorber5.Types of shock absorber

PROJECT PHOTOS:

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INTRODUCTION

SHOCK ABSORBERS :

Shock absorber, device for reducing the effect of a sudden shock by the

dissipation of the shock energy.

When the wheels hit a hole or a raised spot on a road, the springs absorb the

resultant shock by expanding and contracting.

To prevent the springs from shaking the frame excessively, their motion is

restrained by shock absorbers, which are also known by the more descriptive

term dampers.

In order for a spring to expand and contract, it must pull apart and push

together the ends of this shock absorber.

PRINCIPLE: Faradays law of electromagnetic induction.

MAGNET AND COIL:

When a magnet is moved into a coil of wire, changing the magnetic field and

magnetic flux through the coil, a voltage will be generated in the coil according to

Faraday's Law When a magnet is moved into a coil of wire, changing the magnetic

field and magnetic flux through the coil, a voltage will be generated in the coil

according to Faraday's Law.

When the magnet is moved into the coil the measuring meter deflects to the

left in response to the increasing field.

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When the magnet is pulled back out, the measuring meter deflects to the

right in response to the decreasing field. The polarity of the induced EMF is such

that it produces a current whose magnetic field opposes the change that produces

it.

PROJECT IDEA:

The main idea of the project is to make use of this to and fro motion of the

piston and convert it into some useful form of energy other than wasting it

without disturbing the damping facility that is been provided in the shock

absorbers .The useful form of energy that is been obtained from the motion of the

piston is ELECTRICAL ENERGY by using the principle of Faradays Law of

Electromagnetic Induction (i.e. by using the magnet and copper coil as the major

elements).

The power that is generated in this mechanism is generally AC and hence it

is further converted into DC by using a bridge rectifier and makes use this power

supply for charging the battery of the mobile.

For charging the mobile we require just a voltage of 3.5v to a max of 3.8v

which can be easily obtained in this methodology of the project.

Hence for carrying out this project certain modifications have been done

which is discussed in detail below.

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ELECTRICAL CONCEPTS

UNITS:

Electromagnetic units are part of a system of electrical units based primarily upon

the magnetic properties of electric currents, the fundamental SI unit being the

ampere. The units are:

Ampere (current).

Coulomb (charge).

Farad (capacitance).

Henry (inductance).

Ohm (resistance).

Volt (electric potential).

Watt (power).

Tesla (magnetic field).

Weber (flux).

These are some of the electromagnetic units that should be known before the

different electrical or magnetic properties and their fundamental datas are studied

in detail.

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TABLE NO.1

SI electromagnetism unitsSymbol Name of Quantity Derived Units Unit Base Units

I Electric current ampere (SI baseunit) A A (= W/V = C/s)

Q Electric charge coulomb C As

U , V ,; E

Potentialdifference; Electromotive force volt

V J/C = kgm 2s 3 A 1

R; Z ; X Electricresistance; Impedance; Reactance ohm

V/A =kgm 2s 3 A 2

Resistivity ohm metre m kgm 3s 3 A 2

P Electric power watt W VA = kgm 2s 3

C Capacitance farad F C/V =kg 1 m 2 A2s4 E Electric field strength volt per metre V/m N/C = kgmA 1 s 3

D Electric displacement field Coulomb per

square metreC/m 2 Asm 2

Permittivity farad per metre F/m kg 1 m 3 A2s4

e Electric susceptibility (dimensionless) - -

G; Y ; B Conductance; Admittance; Susceptance Siemens S

1 =kg 1 m 2 s3A2

, , Conductivity siemens per metre S/m kg1 m 3 s3A2

B Magnetic flux density, Magneticinduction tesla

T

Wb/m 2 =

kgs2

A1

=NA 1 m 1

Magnetic flux Weber Wb Vs = kgm 2s2 A 1

H Magnetic field strengthampere per meter A/m Am

1

L, M Inductance Henry H Wb/A = Vs/A =kgm 2s 2 A 2

Permeability Henry per metre H/m kgms 2 A 2

Magnetic susceptibility (Unit less) - -

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JOULES LAW:

INTRODUCTION:

When an electric current passes through wire heat energy is produced. Itis due to the collision of electrons with the atoms. In order to continue steadycurrent, work has to be done on electric charges.

STATEMENT:

Amount of work done on electric charge on steady current is directlyproportional to amount of heat.

Work E Heat

PROOF : Consider a conductor through which electric current q is passing intime t let the potential difference between two ends of wire is V .

We know thatv = W/q

(or)W = q x V (i)

According to Ohms law V = IR

Putting the value of V in equation (i)

W = q x IR(ii)

But

I = q/t(Or)

Q = It

Putting the value of Q in equation (ii)

W = It. IR

W = I 2Rt

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OHMS LAW

INTRODUCTION:Ohms law is a quantitative relation b/w potential difference and

electric current.

STATEMENT:

According to Ohms law,

" The electric current passes through a conductor is directly proportionalto the potential differences between the ends of conductor,

if physical conditions of conductor remain constant. "

i.e.I E V

I = kV

K =constant and is called " conductivity of material "

I/K = Vor

V = I/K

V = I x 1/K Let [1/K = resistance]

G RAPHICAL REPRESENTATION

V = I x R

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Galvanometer:Galvanometer is an electromechanical instrument which is used for the

detection of electric currents through a circuit. Being a sensitive instrument,

Galvanometer cannot be used for the measurement of heavy currents .

AMMETER:Ammeter is an electrical measuring device, which is used to measure electric

current through the circuit.

Connection of Ammeter in Circuit : An ammeter is always connected in series to a circuit.

VOLTMETER:Voltmeter is an electrical measuring device, which is used to measure

potential difference between two points in a circuit.

Connection ofVoltmeterin Circuit : Voltmeter is always connected in parallel to a circuit.

PROPERTIES OF MAGNET:

1. Magnets attract objects of iron, cobalt and nickel.

2. The force of attraction of a magnet is greater at its poles than in the middle.

3. Like poles of two magnets repel each other.

4. Opposite poles of two magnets attracts each other.

5. If a bar magnet is suspended by a thread and if it is free to rotate, its South

Pole will move towards the North Pole of the earth and vice versa.

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CHARACTERISTICS OF MAGNETIC LINES OF FORCE :

1. Magnetic lines of force start from the North Pole and end at the South Pole.

2. They are continuous through the body of magnet

3. Magnetic lines of force can pass through iron more easily than air.

4. Two magnetic lines of force cannot intersect each other.

5. They tend to contract longitudinally.

6. They tend to expand laterally .

FERROMAGNETIC SUBSTANCES :

Substances that behave like a magnet in the presence of a magnetic field are

known as Ferromagnetic Substances .

EXAMPLES: Iron, cobalt and nickel are ferromagnetic substances .

LAW OF CONSERVATION OF ENERGY:

According to the law of conservation of energy:

" Energy can neither be created nor it is destroyed, however

energy can be converted from one form energy to any other form of energy "

COULOMB'S LAW:

The magnitude of the force of attraction or repulsion between two electric

charges at rest was studied by Charles Coulomb. He formulated a law, known as

"COULOMB'S LAW ".

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According to Coulomb's law:

1 .The electrostatic force of attraction or repulsion between two point charges

is directly proportional to the product of charges.

2. The electrostatic force of attraction or repulsion between two point charges

is inversely proportional to the square of distance between them.

ELECTRIC FIELD:

When an electric charge is placed in space, the space around the charge is modified

and if we place another test charge within this space, the test charge will

experience some electrostatic force. The modified space around an electric charge

is called 'ELECTRIC FIELD'. For an exact definition we can describe an electric

field as:

Space or region surrounding an electric charge or a charged body withinwhich another charge experiences some electrostatic force of attraction

or repulsion when placed at a point is called Electric Field.

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ELECTRIC INTENSITY:

Electric intensity is the strength of electric field at a point.

Electric intensity at a point is defined as the force experiencedper unit positive charge at a point placed in the electric field.

(OR)

It may also be also defined as the electrostatic force per unit

charge which the field exerts at a point.

Mathematically,

Electric Line Of Force:

An electric line of force is an imaginary continuous line or curve drawn in

an electric field such that tangent to it at any point gives the direction of the

electric force at that point. The direction of a line of force is the direction along

which a small free positive charge will move along the line. It is always directed

from positive charge to negative charge.

E=F/ q

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ELECTRIC FLUX:

Electric flux is defined as:

" The total number of lines of force passing through the unit area of a surface

held perpendicularly. "

" The dot product of electric field intensity (E) and the vector area ( A) is

called electric flux. "

Where is the angle between E and A

MAXIMUM FLUX:

If the surface is placed perpendicular to the electric field then maximum electriclines of force will pass through the surface. Consequently maximum electric fluxwill pass through the surface.

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ZERO FLUX:

If the surface is placed parallel to the electric field then no electric lines of force will pass through the surface. Consequently no electric flux will pass throughthe surface.

MAGNETIC FLUX:

Magnetic flux ( (J ) ) is equal to total number of magnetic lines of force

passing through an area A of any shape.

Unit of magnetic flux is WEBER.

FLUX DENSITY:

It is the number of magnetic lines of force passing through unit area of a surface.

It is denoted by (B). Flux through an area A is given by.

Unit of B is Weber/m 2 or Tesla.

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ELECTRO MAGNETIC INDUCTION-LAWS OF ELECTRO MAGNETIC

INDUCTION:

In 1830 Joseph Henry and Faraday observed that an E.M.F. is setup in a coilplaced in a magnetic field whenever the flux through the coil changes. This effect

is called Electromagnetic Induction.

If the coil forms a part of a close circuit, the E.M.F. causes a current to flow

in the circuit. E.M.F. setup in the coil is called "induced E.M.F" and the current

thus produced is termed as "Induced Current".

Experiments show that the magnitude of E.M.F. depends on the rate at which the

flux through the coil changes. It also depends on the number of turns on the coil.

There are various ways to change magnetic flux of a coil such as;

(1) By changing the relative position of the coil with respect to a magnet.

(2) By changing current in the coil itself.

(3) By changing current in the neighboring coil.

(4) By changing area of a coil placed in the magnetic field etc.

FARADAY S LAW OF ELECTROMAGNETIC INDUCTION :

Faraday was the first scientist who performed a number of experiments to

discover the facts and figures of electromagnetic induction, he formulated the

following law:

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When magnetic flux changes through a circuit, an EMF is induced in it

which lasts only as long as the change in the magnetic flux through the circuit

continues .

Quantitatively, induced EMF is directly proportional to the rate of change of

magnetic flux through the coil.

i.e.

Average EMF = = -N(J /( t

Where N = number of turns in the coil.

The negative sign indicates that the induced current is such that the magnetic

field due to it opposes the magnetic flux producing it.

LENZ S LAW:

Lenzs law in fact describes that in order to produce an induced EMF or induced

current some external source of energy must be supplied otherwise no current

will induce.

Lenzs law states that"

" The direction of induced current is always such as to oppose the cause

which produces it " .

That is why a ve sign is used in Faradays law.

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FARADAY'S LAW

Any change in the magnetic environment of a coil of wire will cause a

voltage (EMF) to be "induced" in the coil. No matter how the change is produced,the voltage will be generated. The change could be produced by changing the

magnetic field strength, moving a magnet toward or away from the coil, moving

the coil into or out of the magnetic field, rotating the coil relative to the magnet,

etc.

Faraday's law is a fundamental relationship which comes from Maxwell'sequations. It serves as a succinct summary of the ways a voltage (or EMF) may be

generated by a changing magnetic environment. The induced EMF in a coil is

equal to the negative of the rate of change of magnetic flux times the number of

turns in the coil. It involves the interaction of charge with magnetic field.

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LENZ'S LAW

When an EMF is generated by a change in magnetic flux according to

Faraday's Law, the polarity of the induced EMF is such that it produces a current

whose magnetic field opposes the change which produces it. The induced magnetic

field inside any loop of wire always acts to keep the magnetic flux in the loop

constant. In the examples below, if the B field is increasing, the induced field acts

in opposition to it. If it is decreasing, the induced field acts in the direction of the

applied field to try to keep it constant .

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MAGNET AND COIL

When a magnet is moved into a coil of wire, changing the magnetic field and

magnetic flux through the coil, a voltage will be generated in the coil according to

Faraday's Law. In the example shown below, when the magnet is moved into the

coil the galvanometer deflects to the left in response to the increasing field.

When the magnet is pulled back out, the galvanometer deflects to the right

in response to the decreasing field. The polarity of the induced EMF is such that it

produces a current whose magnetic field opposes the change that produces it.

The induced magnetic field inside any loop of wire always acts to keep the

magnetic flux in the loop constant. This inherent behavior of generated magnetic

fields is summarized in Lenz's Law .

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SHOCK ABSORBER:

Shock absorber, device for reducing the effect of a sudden shock by the

dissipation of the shock energy. On an automobile, springs and shock absorbers are mounted between the

wheels and the frame.

When the wheels hit a hole or a raised spot on a road, the springs absorb the

resultant shock by expanding and contracting.

To prevent the springs from shaking the frame excessively, their motion is

restrained by shock absorbers, which are also known by the more descriptive

term dampers.

The type of shock absorber found on automobiles is usually a hydraulic type

that has a casing consisting of two tubes, one telescoping into the other.

In order for a spring to expand and contract, it must pull apart and push

together the ends of this shock absorber.

But the ends offer so much resistance that the motion of the spring quickly

dies out.

The ends are connected to a piston in an oil-filled chamber in the shock

absorbers inner tube.

The piston can only move if it forces oil past it through valves. This

arrangement creates a large resistance to any motion by the piston and

consequently by the ends.

On some automobiles a type of hydraulic suspension is used to function bothas a spring and as a shock absorber.

It comprises a sealed spherical container filled with equal volumes of

hydraulic fluid and gas under pressure.

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The compression of the gas, which absorbs the shock, is supplied by the

vehicle's engine. Shock absorbers are used on aircraft to ease the impact upon

landing.

Some machines are mounted on resilient materials composed, e.g., of cork or rubber. The materials act as shock absorbers, isolating the vibrations of the

machine from the surrounding area.

SHOCK ABSORBER

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TYPES OF SHOCK ABSORBER:

Types of shock absorber :

1. Mechanical shock absorber

2. Hydraulic shock absorber

Again the hydraulic shock absorber s are further divided into

1. Van type

2. Piston type

a. Single acting

b.Doubleacting

3. Telescopic type.

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PURPOSE OF SHOCK ABSORBER:

To control the vibrations on springs.

To provide comfortable ride To act flexible and to be rigid enough To resist the unnecessary motion of the springs.

SUSPENSION SYSTEM:

The chassis of the vehicle is connected to the front and rear wheel through

the medium of springs, shock absorbers and axles. All the parts perform the

function of parts from shocks are known as suspension system.

The automobile chassis is connected with the axles indirectly by springs. It

is done to prevent the vehicle body from the road shocks due to form of

bounce,pitch, roll or sway.

It provides an uncomfortable ride and also additional stress in the

automobile frame and body. Both the springing device used and various mountings

are included.

Suspension system has a spring and a damper. The energy of the road shock

produced by the spring oscillates. These oscillations are arrested by the damper known as a shock absorber.

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COMPONENTS OF SUSPENSION SYSTEM:

Spring to neutralize the shocks from the road surface.

Dampers called shock absorbers to improve riding comfort by limiting the

free oscillation of the springs.

Stabilizer called sway bar or anti roll bar to prevent lateral swaying of the

car.

A linkage system holds the above components to control the longitudinal

and lateral movements of the wheels.

FUNCTIONS OR OBJECTIVES OF SUSPENSION SYSTEM :

To eliminate the road shocks from transmission to the vehicle components.

To maintain stability of the vehicle in pitching or rolling while in motion.

To safe guard the occupants from road shocks.

To keep the body perfectly in level while travelling over rough uneven

ground.i.e the up and down movement of the wheels should be relative to the

body.

To minimize the effects of stresses due to road shocks on the mechanism of

the motor vehicle and giving cushioning effect.

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To safe guard the occupants from road shocks and provide riding comfort.

It supports the body on the axles and keeps the proper geometrical

relationship between the body and wheels.

PRINCIPLES OF SUSPENSION SYSTEM:

The weight of the wheels.

Reduction of rolling or pitching of the body to a minimum design and

attachment of the springs.

Absorbing satisfactorily larger and also the smaller road impacts with the

help of a single springing device.

BASIC SUSPENSION MOVEMENTS:

Bouncing Pitching Rolling Yawing

TYPES OF SUSPENSION SPRINGS:

1. Steel Springs

Leaf springs

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Coil springs Torsion springs Tapered leaf springs

2. Rubber Springs

Compression springs Compression shear sprig Steel reinforced spring Progressive spring Face shear spring

3. Air Springs

Bellow type springs

Piston type springs

4. Platic springs

5. Air springs

TYPES OF LEAF SPRINGS:

Semi elliptical springs. Quarter elliptical springs. Three quarter elliptical springs Transverse springs

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Full elliptical springs Platform type springs

TYPES OF SUSPENSION SYSTEM :

Front End Suspension.

Independent Front End Suspension

Rigid axle Front End Suspension

Rear End Suspension.

Longitudinal leaf spring Rear end suspension.

Transverse leaf spring Rear end suspension.

Coil spring Rear end suspension.

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COMPARATIVE SPECIFICATION CHART FOR VARIOUS

INDUSTRIAL PLASTICS:

PROPERTY TestmethodASTM

Units Nylon-6

Delrin/acetal

Polypropylene

Acrylic

MECHANICAL

Tensile strength D638 Kg/cm2 580 740 350 730Elongation atbreak

D638 % 100 60 200-700 4.0

Flexural modulus D790 Kg/cm310^4

1.8 2.6 1.8 32(ICItest)

Impact strength(IZOD)

D256 Ft./lb./.in 1-3.6 1.2-1.6 5-2.0 1.0

Rockwellhardness

D760 M scale Rscale

M-70 MBO_

_ R-95

M102_

THERMALThermalexpansion*10^5

D695 Cm/cm/degree c

7-10 9-5 11.0 8.8

Resistance to heatcontinuous

90 110 105 95degree c

Intermittent Degree c 130 140 150

ELECRICALVolumeresistivity

D257 Ohm cm 10^14-10^15

2.5*10^14

10^18 10^14

DielectricStrength

D149 V/ml 300-480

500 450-600 400

Power factor @60cycle

D150 _ -01 002-003 0.0005 _

@10^6 cycle _ _ .04 .006 0.0005 _

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Note:A - ATTACKED DONOT USE

G - GOOD RESISTANCE

E - EXCELLENT RESISTANCE

TESTING ATMOSPHERIC TEMPERATURE-230C DH-50%

OTHER PROPERTIESSpecific gravity D790 _ 1.14 1.41 0.90 1.18

Water absorption

24hrs

D570 % 1-3.5% 0.22 0.02 0.3

Burning ratio D625 Cm/min Self ext Slow(2.7) slow 3.5

CO-EFFICIENTOF FRICTIONPlastic on steel _ _ 0.11 _ 0.25 _

Steel on plastic _ _ 0.2 _ 0.35 _

RESISTANCECHARACTERISTICS1.Effect to weak acids

D543 - E F E E

2.Effect of strongacids

D543 - A A E E

3. Effect of weak alkalies

D543 - E E E E

4.Effect of strongalkalies

D543 - E E E A

5. effect of organic solvents

D543 - E E G 80c Solubleinketones

6. Resistance tooil

D543 - E G G Solubleinketones

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DESIGN AND FABRICATION:

Design of shock absorber:

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WORKING PRINCIPLE:

The project woks under the principle of Faradays law of electromagnetic

induction.

The shock absorber is designed as per the existing model shown in figure

above.

The copper coil is designed as per the following specifications The diameter of the coil.

Number of turns of the coil. A permanent magnet with high polarities and characteristics and properties

that a magnet should have is used.

The spring of high tension and non-attracting material such as stainless steel

or any other material is made used.

The copper coil is designed as per the following specifications as mentionedabove and it is wound on a material (the material used here is pp-

polypropylene machined as per the design) and it is placed inside the shock

absorber that is designed.

The piston of the shock absorber is replaced by the permanent magnet that isfitted to the stem of the shock absorber piston. The stem is made out of the

nylonmaterial.

Now whenever the vehicle moves in ups and downs, the magnet which isfitted to the piston stem gets compressed along with the spring in such a way

that it moves inside the copper coil that is placed in the shock absorber and

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once the load is removed it retains the original position by the help of the

spring action.

When a magnet is moved into a coil of wire(copper wire coil), it changes themagnetic field and magnetic flux through the coil, a voltage will be

generated in the coil according to Faraday's Law. When the magnet is

moved into the coil the measuring devicedeflects to the left in response to

the increasing field.

When the magnet is pulled back out, the measuring device deflects to theright in response to the decreasing field. The polarity of the induced EMF is

such that it produces a current whose magnetic field opposes the change that

produces it.

Thus the to and fro motion of the piston is converted into electrical energyand this electrical energy thus produced is AC and hence it is further

converted to DC by using a bridge rectifier.

The output of the rectifier (direct current) is connected to the mobile batterycharger and is used to charge the mobile.

The electrical energy can also be used stored in a battery if it is not requiredfor charging of mobile and hence the battery can be used as a secondary

source for the electrical based equipments when the main battery is down.

Hence the name LEVANT (using wasted energy) is given to the title of the project and energy thus obtained can be named as a GREEN

ENERGY.

MODIFICATIONS DONE:

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The shock absorber is designed as per the existing model shown in figure

above.

The copper coil is designed as per the following specifications

The diameter of the coil. Number of turns of the coil.

A permanent magnet with high polarities and characteristics and properties

that a magnet should have is used.

The spring of high tension and non-attracting material such as stainless steelor any other material is made used.

The material used for shock absorbers model are:

Nylon - casing, hub, eye end.

Polypropylene - winding of copper coil wire.

EXPERIMENTS CONDUCTED:

First step:

Material selection selection of what kind of material is suitable

for the shock absorber design keeping in mind about the following aspects.

Strength of the material. Load it has to withstand. Should be a non attractive material. Manufacturing must be easier as per the design.

Cost must be lowSecond step:

Magnet selection 1.the experiment was conducted with ceramic

magnets but it had some limitations such as

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It was not so powerful. And it was not able to

produce the power that we expected.

So we decided to change the magnet.

2. The experiment was conducted by using apowerful permanent magnet. Thus the magnet

was satisfied as it produced the power that we

expected.

Third step:

Copper coil 1.First the bobbin for the winding of copper wire

was machined as per the design required by using polypropylene material.

2. Next the copper wire of diameter 1mm was

wound on the PP material of 500 turns and the magnet was moved in and out

which produced a voltage of 0.5v-1v which was measured by using a

multimeter.

3. Next the number of turns of the copper wire was

increased to 1800 turns and when the magnet was moved in and out

produced a voltage of 2.5v-3.2v measured by using a multimeter.

4. Next we decided to further increase the number

of turns and reduce the diameter of the copper wire.

5.Now the diameter of the wire was reduced to

0.5mm and the number of turns was increased to 2000 turns and we obtained

a voltage of 4.1v-6.2v when the magnet was moved in and out the coil.

6. Finally we decided to increase the number of turns to 4000 of same dia. of copper wire and when the magnetwas moved in

and out produced a maximum voltage of 11.2v-12.1v which we felt that it is

sufficient for the charging of battery.

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Forth step:

Bridge rectifier it is used to convert the AC that is obtained

from the copper coil into DC which is used for

charging of mobile which required 3.5v-3.8v andwas easily obtained by using the magnet and coil

as specified.

Further progress on the project:

This project is just an idea that it is possible of producing power from the to

and fro motion of the piston and we proved by getting a model out of that.

But it is not the end to the project as it is not feasible of using this in heavy

vehicles, and our aim is to imply the concept in regular shock absorbers that we

use in our vehicles.

Hence the modifications for further progress on the project are done as given

below.

The shock absorber is not going to be changed instead a link is

provided in such a way that when the piston moves downwards

(contracts) simultaneously the magnet on the other hand moves upwards

inside the coil arrangement and when the piston moves upwards

(expands) the magnet on the other hand moves downwards inside the

coil arrangement which results in electrical energy. Thus the reducing

the effect of a sudden shock by the dissipation of the shock energy by the

shock energy. On the other hand electrical energy is been produced

constantly.

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COST ESTIMATION:

Sl.no MATERIAL COST OF THEMATERIAL

1. NYLON

MATERIAL

1550/-

2. MAGNET 750/-

3. SPRING 250/-

4. ELECTRICALEQUIPMENTS

400/-

5. MISCELLANEOUSEXPENSES

500/-

TOTAL COST 3690/-

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CONCLUSION:

DEMAND FOR ENERGY IS INCREASING DAY BY DAY.SO

WE NEED AN ALTERNATIVE SOURCE TO COMPENSATE

THE INCREASING DEMAND OF ENERGY.

HENCEMAKE SURE THAT WE ARE ABLE TO UTILISE ALL

FORMS OF ENERGY THAT ARE EXISTING IN DIFFERENT

FORMS BY USING SUITABLE DEVICES AND

TECHNIQUES RATHER THAN WASTING THEM.

SAVE ENERGY AND LIVE AND ENJOY WITH ENERGY