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1. Introduction

Our world as we know it is faced with a major energy problem. In order to enjoy Our
world as we know it is faced with a major energy problem. We all enjoy technology and
the modern innovations on a day to day basis. Cellular phones, laptops and even basic
necessities such as the stove, kettle and geyser are innovations which require electricity.
Electricity production in South Africa was not an area of concern during the apartheid
era. Focus and attention was only given to the superior race of the time and all others
were ignored. The government ensured that white people of the country had their needs
taken care of and were living a comfortable lifestyle. This included the constant supply of
running water, electricity and easy access to their places of interest.
However whilst all attention was given to the superior race, the majority of the country
were suffering from discrimination as well as lacked basic necessities. Besides clean
running water, they were placed in the furthermost parts of the country which were
isolated areas.
The government was satisfied with this organization of inhabitants of the country and as
long as the superiors had a constant supply of electricity there was little concern for
anyone else.
Power generation was through coal power stations and the supply exceeded the demand
therefore there was little concern towards the future of power generation in South Africa.

After the Apartheid era, privileges due to race were abandoned and all South Africans
were given an equal opportunity. This meant that the majority of the country which was
previously placed in rural areas became urbanized. The need for electricity had started to
escalate.
In order to accommodate this increase in demand, more coal, an indigenous resource was
used and slowly more power stations were being built. By early 2008, South Africa had
become a strong economically developing country, with rapid industrialisation. This led
to the demand exceeding supply.
The leading power generation company in South Africa, Eskom, had embarked on a
massive programme to upgrade the countrys electricity infrastructure.
A R343-billion five year project to start up two new coal powered stations was the major
part of Eskoms project.
A nuclear power plant was also on the agenda however, funding from overseas was
required. There were also plans of a hydro scheme in the Drakensberg, Kwa-Zulu Natal
and re-opening of two open-cycle gas turbines.

Energy provides about 15% to the countrys gross domestic product (GDP). Eskom is one
of the worlds biggest electricity generators, and provides approximately 95%of South
Africas power. The national grid is about 27000 kilometers of power lines.






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We are privileged to have in this day and age, many innovations however we have used
up many of our resources without thought towards the future. The exploitation of non-
renewable resources, such as fossil fuels, has proved to be detrimental to the quality of
our planet. The consequence thereof is global warming, which is proved by melting of the
polar ice caps and the variation in temperature patterns. Many have predicted the end of
the world within the next decade due to the excessive use of precious resources and no
sense of gratitude or appreciation. We have become greedy for development and
improvement in the current technology so much so, we have failed to take care of our
resources. Therefore, it is vital that we find ways and means of continually producing the
required energy whilst keeping in mind the needs of future generations.

According to Creamer Medias Engineering News on 5 April 2012, the power
consumption increased by 1.8% in February from a year earlier. However, the production
only increased by 0.5%. in January 2012, electricity consumption was 19 676GWh.
Eskom contributes 19 410GWh of the 20 292GWh of electricity produced in a month in
South Africa. These statistics were provided by Stats SA in this article.

Since South Africa is currently facing a major energy crisis and our demand is exceeding
the supply, we have experienced load shedding throughout the country and have become
liable to an increase in the cost of utility bills.
Other methods of trying to decrease the supply have been implemented such as electricity
warnings displayed on local television channels. This particular method is effective
because most people are at home in the evenings and television has become an integral
part of daily life.
Winter demands an increased supply of electricity due to heaters and warming elements
being constantly used. This causes the demand for electricity to fluctuate according to the
needs of the community. Necessities such as street lamps use a lot of power during the
evenings and have to be constantly supplied throughout the year. The energy crisis forces
us to start taking responsibility of our actions when using resources, therefore a demand
for renewable resources.

The use of nuclear power plants is an existing design and is being implemented in South
Africa. However, it poses an extreme health risk if failure occurs. This has recently
occurred in Tokyo,Japan. After the Fukushima disaster where a tsunami followed an
earthquake and disabled the power supply. All three cores of the nuclear power plant
were largely melted and therefore high radioactive releases.
Japan used nuclear power since 1970 and it contributed 30%to the annual power
generation in the country. This disaster has therefore caused an expected shortage of
electricity in the near future.

Synthetic fuels, oils and gas have been provided by South Africa leading company on the
JSE stock Market, Sasol. Sasol has a plant in Secunda, Mpumalanga where it coverts gas
to more environmentally friendly liquids.




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The planet provides many natural phenomena and it is important that we utilize these
existing forms of resources. Such phenomena are wave power, solar and wind energy.
Whilst many methods and designs have been made in respect to these phenomena, it is
also possible to improve on modern innovations to provide suitable amount of power.
We are consistently improving technology and it has become important to keep the
environment and power usage in mind. The planet requires responsible inhabitants
presently and in future generations. Renewable energy is the solution to the energy crisis
and will have a positive impact in the future.

According to Creamer Medias Engineering News on 5 April 2012, the power
consumption increased by 1.8% in February from a year earlier. However, the production
only increased by 0.5%. in January 2012, electricity consumption was 19 676GWh.
Eskom contributes 19 410GWh of the 20 292GWh of electricity produced in a month in
South Africa. These statistics were provided by Stats SA in this article.

Ref: www.enginneringnews.co.za/article/february-power-consumption
www.world-nuclear.org/info/fukushima_accident_inf129.html
www.southafrica.info/business/economy/infrastructure/energy.htm#plan





























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1.1Speed Bumps

Speed bumps have the connotation of coffee spills and thus discomfort to a journey, but
we would like to change this in a positive manner. Besides slowing down a vehicle, we
aim to use the weight of the car as it passes the speed bump to generate electricity. For
this, we have chosen to use a hydraulic system whereby the force generated from the
weight of the car will cause a piston to be pushed down and thus fluid flow towards a
hydraulic motor which will allow the production of electricity once coupled to a
generator. We have chosen this method as it is reliable, does not require a lot of
maintenance and the fluid is incompressible.
Speed bumps are operational throughout South Africa and implementing a system to
generate electricity within a speed bump will be resourceful and very effective. The
electricity generated could be used to power up street lamps and nearby facilities. The
system will allow a decrease in the power required from the national grid, and if it is
implemented around the country a significant amount of electricity demanded will be
adhered to.

1.2Traffic Tunnels

Traffic tunnels see a large amount of vehicles passing through it every day. These
vehicles displace large amount of wind as they pass through the air traveling at speeds of
around 45km/h to 120km/h. All this wind energy that is been created by the passing
vehicle is simply getting lost.
The conceptual design that is in the report is an idea to capture the wind that passing
vehicles are displacing and convert it to mechanical energy and then into electrical
energy to power tunnels, lights, extractor fan and traffic signs etc. The conceptual design
uses a vertical turbine as it is more compact and has a lower starting speed than the
everyday horizontal wind turbine.
The reason we went with a drag vertical turbine, is that it required less space for
operation and can be implanted into current traffic tunnels or knew tunnels can be
designed around the idea of having these vertical turbine running down the side of the
wall.













RENEWABLE POWER GENERATION
SPEED BUMPS TRAFFIC TUNNELS
HYDRAULIC SYSTEM WIND TURBINE

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2. Literature review

2.1Speed Bumps

The project required a lot of research and self study. Research was the first step in the
design process because it was vital to read up on existing designs and to appreciate the
ideas of others.

Research enabled us to find ideas and basic designs which already existed. Each design
used the basic concept of converting kinetic energy into electrical energy. These designs
included the use of a pneumatic system due to its simplicity and relatively safe working
pressures. However, components could be damaged due to contamination of the air in a
dirty environment. In order for the system to function, high pressures of air in large
volumes would be needed; some of this volume may be lost due to compression of the
vehicle therefore producing a less efficient system. Air is drawn from the atmosphere
therefore a filter is required as well as a compressor to ensure the air is at a high pressure.
A cooler and air treatment unit would also be required as air contains water vapour and
this needs to be condensed.

A mechanical design was also an option but proved to be inefficient. The rack and pinion,
crank shafts and gear trains which would be involved would require constant
maintenance. Damage to key components would be caused from low impact high
frequency traffic pulses which would be converted to a high speed rotational movement.
Bearings would be needed for a crank shaft which would lead to problems with balancing
and since the loads will be variable, vibrations would become challenging.
Electromagnetic induction could also be used for the design but there would be a
fluctuating frequency of movement within a coil to generate electricity. This fluctuation
would render the system inefficient.

Regenerative braking was another design approach which could be taken but we
preferred a system within the speed bump itself. There are many complications with the
friction brake on an incline, two-wheel drive vehicles and wet surfaces.
Therefore a hydraulic system would be used whereby the inconsistency of traffic would
be compensated for by the use of an accumulator. A hydraulic system is known for high
impact force applications and is best suited design for our project. It will operate at all
temperatures and it is closed off to the environment, preventing contamination. (Ref 2)

Research was also required for the understanding of system components and the reasons
for selecting these specific components. There are many different innovations that can be
used for a broader function but in order to gain maximum efficiency it is important to
narrow down the choices for specific requirements. In order to attain this it was important
to thoroughly research the required components, its materials, availability and cost.
Specific companies had to be researched and catalogues attained in order to meet system
requirements. There were also standards which were used for components such as piping,
bearings, bolts etc.


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2.2 Traffic Tunnels

Vertical axis wind turbine can catch the wind from all direction and at a low speed than
horizontal axis turbine.
There have been two distinct types of vertical axis turbine. The Darius and the Savonius
types. The Darius turbine was researched and developed by the Sandia National Laborites
in the 1980s.

Horizontal axis wind turbine are typically more efficient at converting energy to
electricity than vertical axis wind turbine.
However, smaller vertical axis turbine are more suited to urban areas as they tend to be
more silent and reduce the risk associated with slower rates of rotation.

There was blog about a Arizona student that came up with an idea to use a horizontal
wind turbine that would be placed above a high way that will recapture energy caused by
moving cars on a freeway. (Ref: http://green.autoblog.com/2007/05/01/highway-wind-
turbines-to-capture-energy-from-passing-vehicles/).

By doing more research we were able to come up with a conceptual design. We found
that a vertical wind turbine that is been manufactured and install in urban areas. We were
able to take that idea and design our vertical wind turbine, to be installed in existing as
well as in new tunnels that will use the wind energy and convert it to mechanical energy.
(Ref: http://www.silentwindturbine.com/)























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3. Conceptual Design


3.1 Speed humps

The conceptual design was basic ideas which the group had sketched and decided upon a
final design. Constraints were placed on the design and targets set out.
We experienced constraints such as the size of the system which would be able to fit into
a standard 2mx 500 mm speed bump. The consistency of traffic along the road where
speed bumps are in existence was very influential in the design. Inconsistent traffic would
allow very little power to be generated whilst consistent traffic will be very useful and
increase the efficiency of the system.
The need for such a system was prevalent in DUT itself. There is a constant flow of
traffic around Steve Biko Campus due to taxis, buses and cars which transport students to
and from campus on a daily basis. However in the evenings, students use the library and
there is not sufficient lighting to increase safety. Therefore we decided that the electricity
produced would be used to power up street lamps in and around campus. Generation of
10kW of electricity would power up 100 streetlamps since 100W of electricity is used by
a single streetlamp.
The system could be used at toll gates and used to power up signs and streetlamps around
the area.
The conceptual design can be found in the annexure.


3.2 Traffic Tunnels


The conceptual design the group chose to go with was a four blade vertical turbine that
will capture the wind produced by passing vehicle in a closed tunnel. The total height of
the unit would be 1.5m and this is under the maximum high in a traffic tunnel.
The plan is to design a curved blade that will capture more wind and force the wind
downwards towards the gear box so it can also be used a cooling unit.
The blade would have two support spaced at either end of the blade and would be 1m
apart. The supports would be bolted to the main drive shaft.
The gearbox will house the gears as well as act as a support for the blade assembly.
The reason for a gearbox and not to connect the drive shaft straight to the generator is
that blade as a low speed and in order for the generator and our system to be more
efficient, the speed need to increase and a gearbox was the only way with less loss.
The gear of choice is a spur gear and the reason for this is it can change the vertical
motion to a horizontal so there is less height.

The system we designing can be used to power the lights in the tunnel which will make
the tunnel self maintained as well as the power can be used to power local businesses or
houses near the tunnel



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4. Design

4.1. Speed Bumps

The hydraulic system which will be used will make use of the weight of the car as it
passes over a speed bump. The natural phenomena of gravity allows the use of weight,
this downward force will be used on pistons. There will be 8 pistons used to acquire
maximum force from the movement of the car. The strategically placed pistons will
transfer the force into a pressure of fluid. The fluid will flow along piping through to an
accumulator. The accumulator will store the energy until a suitable working pressure is
reached. Once this pressure is reached, the fluid will flow towards the hydraulic motor
passing a nozzle which would allow an increased velocity. The increased velocity will be
important for functioning of the hydraulic motor. A generator will be coupled to the
motor and once electricity is produced it will be stored in battery banks. This electricity
will now be used when needed. The system also contains many valves to control flow and
pressure. Check valves will be used to ensure flow in one direction and ball valves serves
as isolation valves. These valves will allow maintenance of the system. Since this is a
closed system, after flowing through the hydraulic motor, the fluid will pass through a
filter and thereafter back to the reservoir. The purpose of the filter is to eliminate any
impurities which have contaminated the hydraulic fluid from the components in the
system.

























Shazeem Tulsi

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4.1.1 Fluid selection

Hydraulic fluids are abundantly used in industry. These fluids are required to transmit
motion and generate motion efficiently when a pressure is applied. Hydraulic fluid is also
required to lubricate moving parts, provide a means of cooling, carry away contamination
and prevent wear and corrosion.
Viscosity, a measure of a fluids resistance to motion, is one of the most important
properties of hydraulic fluids. The fluid must provide a good seal at motors, valves etc so
that pressures may be maintained. Leakages within the system will result in a loss of
pressure, affect control aspects instantaneously and the overall efficiency. Liquids that
have a low viscosity and thus too thin, will allow rapid wear of moving parts and parts
affected by a heavy load. However, fluids which are too thick having a high viscosity will
cause internal friction and thus slow down provide unnecessary pressure drops. The
lubricating power, chemical stability, toxicity demulsibility is also very important. The
liquid should also be free from acids and therefore become corrosive resistant. Another
important factor when choosing a hydraulic fluid is filterability. Cleanliness is defined as
the amount of dirt particles oil can tolerate without losing performance. Filters are very
common in hydraulic systems and improved cleanliness allows for longer lasting filters.
There are many types of hydraulic fluids but the most common is mineral oil (petroleum
based). (ref3)
White mineral oil was chosen for the design due to its low viscosity and adheres to the
FDA Regulation. It proves to be beneficial and suitable for the system with regards to the
above mentioned requirements of a hydraulic fluid. (Annexure 1)


4.1.2 Motor selection

One of the major components in the design is a hydraulic motor. Hydraulic motors are
used to convert flow of a liquid under high pressure into mechanical rotation. A
hydraulic motor is known as the reverse of a hydraulic pump, instead of creating a
movement of liquid by mechanical parts acting upon it, a hydraulic motor causes rotation
by the movement of liquid.

There are many types of motors namely, gear, vane, gerotor and radial piston motors. The
gear and vane motor have a low initial cost and high rpm. A gerotor motor has low-to-
medium speed and medium-to-high torque. For the system we needed a motor which
would function at a low speed yet develop high power. Therefore a radial piston motor
was chosen.
The motor that was initially chosen was the GM05 (60) motor which would be supplied
by SAI Hydraulics. They are a reputable company with respect to the manufacture of
hydraulic motors in South Africa. However due to changes the motor specifications did
not meet the system requirements therefore the motor is now a KPM HMB 100 from
BMG Hydraulics. (Annexure 2)



Shazeem Tulsi

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4.1.3 Return mechanism-Spring

It was very important to have a mechanism which would allow the pistons to return to its
original position after a vehicle has passed. Efficiency, reliability and maintenance were
very important for this design. Due to these factors a spring was chosen as the return
mechanism. A spring will allow for easy maintenance as it can be replaced when needed.
The spring would have a pin which would allow the replacement of the spring.

There are many types of springs which can be used based on the material.
Music wire proved to be inefficient as it has a small wire diameter range. This range
makes it suitable for small load operations. It operates at temperatures up to 120C.
Hard-drawn wire is the cheapest type of spring however it is used where life, accuracy
and deflection are extremely important.
Chrome-silicone is the best type of material for high stresses and endurance but is
extremely expensive.

The chosen spring type is Chrome Vanadium. A chrome vanadium spring is most
popularly used. It is an alloy spring steel for conditions involving high stress. It has a
good fatigue resistance and endurance. The spring would also be excellent for shock and
impact loads and withstand temperatures up to 220C. The diameter range is greater than
music wire and is also cost effective.
This spring would undergo inconsistent compression and expansion due to the
inconsistency in traffic. Therefore its property of excellence in shock and impact loads is
beneficial for the design. Cost is a very important factor and is another reason for choice
of spring. (ref 4)






















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4.1.4 Piping

For a hydraulic system, pipe design is of significant importance. Component selection in
a process system is priority however it is also important for smaller equipment such as
piping which, if failure occurs can cause major damage to the larger equipment and thus
extra cost to the system. It is known that most process system failures occur at points
within the piping, flanges, valves, fittings etc. Therefore it is vital to select components
which are compatible with one another.
Material selection of piping is based on liquid properties and flow characteristics. These
include viscosity, density, temperature, Reynolds number and velocity. Material
suitability is also based on valid codes and applications and requires reviewing for safety
purposes. The commonly used code is American Society of Mechanical Engineering
(ASME) Code for Pressure Piping, B31. The environment has to be taken into
consideration to avoid corrosion and temperature changes of the pipeline or fluid.
Temperature changes can lead to thermal expansion and therefore damage to the system.
Pipe sizing is also considered in the process system. Process efficiency can be increased
by ensuring that the liquid flow is optimal. There is an allowable pressure drop which is
influenced by the requirements of the process, safety and vibration limitations.
Pressure drop is the allowable loss in pressure due to frictional losses along the pipeline.
This friction is resistance of flow and therefore reduces process efficiency. Pressure drops
are inevitable within a system however large pressure drops depict that the resistance to
flow is unfavorably large.




Typical piping
Pictures compliments of Valves Africa PTY (LTD)




Shazeem Tulsi

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4.1.5 Valves

In any hydraulic system it is very important to control flow. This can be done by
regulating flow or directing the flow by operating in positions such as fully opened, fully
closed or partially obstructs the flow. Valves can either be manually operated or
automatic where a change in pressure or temperature will actuate the valve.
There are different types of valves for different uses. Some of these include globe,
butterfly, check and ball valves. Valves may have two or three ports in which one or two
of the ports are inlet or outlet.

In our system it was very important to control the direction of flow since it requires oil to
flow in one direction. Flow which is bi-directional could cause damage to system
components. Therefore check valves were needed for this function.

Check valves are two-port valves which allow flow in one direction. This means that they
have two openings, an inlet and outlet. They are automatically controlled and are cost
effective simple and small in size.
For a selection of a valve, the cracking pressure is vital. This is the minimum upstream at
which a valve will operate. Check valves are designed on the basis of the cracking
pressure and thus selected accordingly.
















Check Valve
Pictures compliments of Valves Africa PTY (LTD)







Shazeem Tulsi

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Another valve which was crucial for efficient operation of the system over a period of
time is an isolation valve. This valve would have a lever to allow the flow to be stopped
and therefore replacement of the system components can occur for regular maintenance
of fault in the system.
All isolation valves were chosen which have the same size as the pipe diameter therefore
not allowing any pressure drop.

Valves have been selected according to working pressures, pipe diameter, availability and
durability.





















Isolation Valve
Pictures compliments of Valves Africa PTY (LTD)

Shazeem Tulsi

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Flange pipe joint

Hydraulic pipe joints are generally oval flanges which are fastened by use of two bolts.
Oval flanges are used for small diameter pipes that are upto175mm diameter. Flanges are
generally cast integral with the pipe ends and are used to carry fluid pressure ranging
from 5 to 14Mpa.

Flange joints are the most widely used pipe joint. The joint can be made leak proof by
placing packing between the flanges. The pipe can also be strengthened for higher
pressures and large diameters by placing ribs between the bolt holes.












Socket or a couple joint

This type of pipe joint is one of the most common joints however it is mostly used for
pipes carrying water at low pressures.











Shazeem Tulsi

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Nipple joint

A small piece of pipe threaded outside is screwed in the internally threaded end of each
pipe therefore decreasing the area of flow.



Union joint

This joint allows for disengaging pipes by a simple coupler nut.



Spigot and socket joint

Used for underground piping. It had an advantage of flexibility and can adjust due to the
change in level of earth which is caused by climate and environmental conditions.

Expansion joint
An expansion joint is mainly used for pipes which carry steam at high pressures. It
accommodates for expansion and contraction due to change in temperatures.

Ref: A Textbook of Machine Design by R.S.KHURMI AND J.K.GUPTA (pdf)






Shazeem Tulsi

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4.1.6 Control

Pressure Switch

A pressure switch is a switch mechanism that will initiate an electrical connection when a
specific amount of pressure is placed on the switch.
It is typically a contact switch which means it fits into a container of liquid and measures
the pressure. A pressure switch is made up of two parts, a transducer and a switch. The
transducer identifies increasing and decreasing pressures or even multiples of pressure
points. Once a specific pressure is reached, it will send a signal to the switch unit. The
switch unit will now convert this signal to electrical energy. This energy then allows the
next part of the process to occur.
In this project the hydraulic switch is used in combination with the accumulator. The
accumulator will build up and release pressure and may even experience multiples of the
basic pressure. Due to inconsistency in traffic the fluid flow is not constant and therefore
the accumulator will be subjected to varying pressures. The pressure switch will allow the
fluid to be stored in the accumulator until a pressure of 5.12MPa is reached. Once this
pressure is released it will allow the fluid to flow towards the next component being the
nozzle.

Pressure switches are available with various ranges and different settings, therefore
selection of these switches are based on each application specification. Availability and
standards is also important when selecting this component. Liquids vary in viscosity and
therefore the pressure switch should be functional for the liquids viscosity. However,
most pressure switches can accommodate majority of hydraulic fluids.

The pressure switch selected for this application is adjustable from 12-150 Bar with a
repeatability of 2% of setting. The model is IPH-150 from BMG Hydraulics.

www.thomasnet.com/articles/instruments
www.wisegeek.com/what-are-pressure-switches
www.bmghydraulics.net














Shazeem Tulsi

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4.1.7 Rectifier Circuit

A rectifier circuit is required for conversion of AC to DC from the generator for storage
in batteries.

A rectifier circuit has the purpose of converting an incoming ac signal from a power
source to a pulsating dc current. This means that the rectifier takes current which is
flowing alternately in both directions and modifies it so that it only flows in one
direction. This is illustrated in the figures below.

DIAGRAMS











There are two types of rectifiers:
Half Wave rectifiers
Full Wave rectifiers

A half wave rectifier circuit is very simple and cheap to produce. It makes use of a diode
to either use the positive or negative half cycles to have an output voltage as positive or
negative dc component. Since only half the signal is used the circuit is inefficient,

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wasting energy in the other half of the waveform, it is used in low-current, non-critical
applications.

The diagram below shows the half wave rectifier circuit.




A full wave rectifier circuit

It would be more efficient to use both halves of the input waveform and have more
energy available at the output. The output is now positive pulsating dc where the
frequency has doubled therefore a smoother output.
Within this type of rectifier circuit there is the full-wave centre-tapped rectifier and the
full-wave bridge rectifier
A full wave bridge rectifier has advantages over the centre-tapped rectifier such as; no
centre tapped transformer is required, the output voltage is double the secondary voltage
of the transformer and the circuit uses more efficient diodes.
The four diodes in a diamond shape serves well to provide ac rectification. It is similar to
resistors in a Wheatstone bridge.
Using the diagram below, we can understand the operation of the circuit.



During the positive-half cycle, shown in red, the transformer pushes electrons through the
forward-bi1.ased D3, and then through the load resistor. Forward biased D2 has
electrons flowing through it and then to the top of the transformer winding. This is a
complete circuit therefore current can flow. During this, D1 and D4 are reversed biased
and do not conduct any current.
Shazeem Tulsi

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Now, during the negative half- cycle, D1 and D4 are forward-biased and D2 and D3 are
revers-biased. Therefore electrons flow through D1 and D4 as shown by the blue arrows.

With this type of arrangement the diodes keep switching the transformer connections to
the resistor. The resistor can be replaced with a filter and have a regulator follow to allow
for a smoother output voltage.

Ref: 1) www.Play-hookey.com/ac_theory/ps_rectifiers.html
2) Introductory Electronics for Engineering
Martin Podges
ISBN 0 7021 5214 5
3) Electronic Devices conventional Current version Eighth edition
Thomas L Floyd
ISBN 0 13 615581 2































Shazeem Tulsi

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4.1.6.3 P&ID Diagram

Process and Instrument Diagram is a diagram which shows all process fluid lines,
instrumentation, instrumentation signals and equipment.

Instrument identification is extremely important in understanding a control loop.
Standards such as The Instrumentation, Systems and Automation Society (ASI) of the
United states of America is used in industry.

A circle with two or more letters is used to label instruments and the number corresponds
to the tag number.
In the case of faults, the tag number allows for efficient documentation at replacement.
The function of the instrument is indicated by the second letter in the circle.

Below is a basic Process and Instrumentation Diagram of the design for the hydraulic
system.





Piston Bladder Accumulator Isolation valve Check Valve Hydraulic motor Filter

Reference:
van Vuuren G, An Introduction to Process instrumentation, 3
rd
Edition, quad
Technologies. Durban, 2002
www.googleimages.com 03 May 2012
Shazeem Tulsi

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Generator selection

A GL-PMG-5000 generator was selected due to the fact that it needs a minimum of 3.5
rpm to keep the shaft rotating and it is cost effective. This generator is made of alloy steel
which has anti-corrosion treatment and it has a life time of more than twenty years which
means there is less maintenance required.
Graphs depict the power and voltage achieved.
It can

It can be seen from the above graph that 300 rpm cant be achieved so 250 rpm was
selected and from the graph approximately 70KW power is generated



Using 200 RPM a voltage of nearly 650 V is achieved


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4.1. Traffic Tunnel Design

The vertical blade turbine design that was chosen is a drag turbine. This uses the thrust
force of the wind to push the wind turbine and make it rotate about it axis. This is a way of
converting wind energy into mechanical energy.
This concept has been adapted to use the wind produced by cars traveling @ 45Km/h to
100Km/h. The reason for going with this design is because other vertical turbine needed
a large working diameter to operate efficient.
By going with the drag turbine we would need less space which made the turbine more
efficient an allow it to be incorporated into current traffic tunnels or into knew tunnels
that are still be designed.
How this turbine works it that it captures the wind energy as the vehicles pass it and turns
a shaft. The shaft is then connected to a gearbox where the low speed of the blades is
converted to a higher out speed by means of a gearbox. The gearbox allows the generator
to rotate at maximum speed without having the blades turn fast. The electricity that the
generator generates is then stored in numerous batteries.


Lendell Beaumont

23

The idea is to take the vertical turbine an place it on the one side of double
flowing traffic or two place it in the centre so it receives wind from both lanes
traveling in opposite directions



The above images display the available space in a box tunnel or an arch tunnel.
Our design has an outer diameter of 1m and a height clearance of 1800mm.








Lendell Beaumont

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4.1.2. Energy in Wind

We know that



Where m = mass (kg)
V = velocity (m/s)
Energy (Joules) = kg m2 / s2



Energy in a finite mass of air moving at a certain velocity:

Kinetic Energy of a finite mass of air



Power produced by a finite mass of air:
Energy (Joules) / time = power (Watts)

Let us assume that the finite mass of the air in consideration is passing through a hoop where
it transfers its energy to an imaginary plate place at the entrance of the hoop.

Mass of air going through the hoop per second:


Where:
A = cross sectional area of the hoop
= air density (mass/volume)

Power of a mass of wind blowing through a HOOP at a certain rate (velocity):



Energy Conversion Efficiency:
We cannot convert all of the power in the wind to Mechanical (then electrical) power.
According to Belts, Maximum theoretical power conversion efficiency (wind to mechanical)
is 59% (0.59, Beltz limit).
Maximum mechanical power extracted from wind blowing through a HOOP at a certain rate
(velocity):



The losses are typically caused by aerodynamic drag, frictional losses due to high wind
velocity and wind turbulence.







Lendell Beaumont

25





Torque on the shaft created by the wind



Where:
T = Torque
F = Force
r = radius















Lendell Beaumont

26
4.1.2. Blade

The blade is the most important part of the design. It needs to be light but also rigid to
avoid shattering as this could cause major damage in a tunnel. To install anything into a
tunnel we had to keep to the tunnel specification. The blade would need to take pressure
created from the wind as well as centrifugal forces as it taking a linear velocity and
turning it into an angular motion.
The blade is of a simple design we it is just a flat plate that get pushed by the wind.
Although it looks simple the size and strength had to work out to make it very efficient as
weight is a big problem when making the blades move.
As you can see in figure 1 the different material that was tested gave different deflection
readings. Although steel gave the least deflection it was too heavy and the weight alone
single it out as it will not work. Other material like aluminum and fiberglass was tested.
The aluminum gave nice low reading but again it was still too heavy. The fiberglass was
light but it deflection was too high as it will shatter in a tunnel if something goes wrong.
It was found by fusing fiberglass and aluminum together we could come up with a
stronger and lighter material of the two as you can see on figure 1 below.

4.1.2.3. Results


Figure 1 Deflection of the Blade
The maximum shear stress occurs along the neutral axis where a bending moment
occurs.
As you can see in the graph below when using aluminum or steel they experience a much
lower stress than that of the composite material. This is due to the fact that it is one solid
piece and does not have any joints. Although in the graph the steel or aluminum is the
best they still have a weight factor that prevents us from using it.
If you look at the composite material is subjected to a max shear stress of 2.5MPa in the
fiberglass. This is well acceptable as the maximum shear stress the fiberglass can take
before failure is
-0.0001
-0.00008
-0.00006
-0.00004
-0.00002
0
0 0.1 0.2 0.3 0.4 0.5
D
e
f
l
e
c
t
i
o
n

Distance
Deflection On a Blade Caused by 90N
Force
Aluminum
Steel
Fibre Glass
Composite Material
Lendell Beaumont

27

Graph 1 Shear Stress against distance from centered


4.1.2.3. Manufactoring Process

The manufacturing process to make the blade is the most important. The process sees
bonding of the aluminum piece to the outer fiberglass. The process is done a few steps.
First the aluminum piece is cut into the correct size.
Then it is taken to a press where the wholes for the bolts to go through are press out.
An alloy base is casing holds one layer of fiberglass
Epoxy is pour on to the fiber glass and is spread out equally.
A 2
nd
layer of fiberglass is laid on top of the epoxy and epoxy is then poured over the
fiberglass.
This is done for 3 layers to get a required thickness of 3mm.
After the 3 layer of fiberglass is laid down, epoxy is again laid down.
The epoxy helps join the fiberglass together as it acts as an adhesive.
The aluminum core is then laid onto of the epoxy and the same procedure follows
backwards for laying the fiberglass.
The top casing is then put on to the entire mold.
The casing with mold inside is then taken to a press that heats the casing and press all the
material together.
The heat helps to melt the epoxy, so it gets distributed evenly and the pressure push out
any air spaces.
The mold is then removed and left to cool down.
The excess fiberglass is shaved off by a bench grinder and the wholes are punched
through the fiberglass to allow for the bolts to go through





-0.006
-0.004
-0.002
0
0.002
0.004
0.006
-
3
.
0
0
E
+
0
5
-
2
.
0
0
E
+
0
5
-
1
.
0
0
E
+
0
5
0
.
0
0
E
+
0
0
1
.
0
0
E
+
0
5
2
.
0
0
E
+
0
5
3
.
0
0
E
+
0
5
D
i
s
t
a
n
c
e

m

Shear Stress
Shear Stress vs distance
Composite
Aluminium
Steel
Lendell Beaumont

28

4.2.3. Connecting Arm

4.2.3.1. The support beam would have to accommodate the following
effect to be used:

Will be subjected to a force pushing it down due to gravity
Would be subjected to a centrifugal force
Would need to be light
The material need to be coated to protect it from corrosion
There will be two loads acting on the x-axis as well as the y-axis. These
two loads will cause bending and shearing in the welds. Therefore the
material would have to be strong to with stand these stresses and must be
light so the blade can turn will a little amount of wind.

4.2.3.2. Results

The maximum Yield strength for steel is 250MPa, Ultimate strength is 400MPa

There will be a moment on the x-axis as 0.42Nm and 8.1Nm in the y-axis

The first step taken was to calculate the second moment of inertia for the x-axis
and y-axis for two different size materials.

The stress was then calculated as well as the bending in the flat bar. In the table
below you can see the stress of the beam at different places on the beam. It can be
seen that the 3mm plate is much higher than the 6mm plate but it is still bellow
the maximum strength of the material.


3mm thick 6mm thick

180.93MPa 45.47MPa

-179MPa -44.5MPa

179MPa 44.5MPa

-181MPa -45.5MPa


From this we decided to go with the 3mm plate as weight is a big factor for our
design and it will stand up to the condition.







Lendell Beaumont

29


4.2.3.3. Manufacturing Process

The parts of the beam would be fabricated separate and will be brought together in a
jig and welded. The process will be listed below:

4.2.3.3.1. There are two piece made from 5 X 30mm flat bar. The bar is
supplied in 3m lengths.
4.2.3.3.2. The flat bar would be cut into 3m length so it can be easier handled
4.2.3.3.3. The bar is taken to a punch machine where two holes 12mm in
diameter are punched in ever 100mm length piece.
4.2.3.3.4. The 3m length bar is then taken to a galantine where it is cut into it
100mm length.
4.2.3.3.5. A slot of 22 x 50mm is cut into each 100mm flat as this is where
the round pipe would be welded on.
4.2.3.3.6. A round pipe of nominal bore 15mm will be cut into 250 mm long
pieces with the use of a bench jig saw.
4.2.3.3.7. The round pipe will be placed into a jig and 5 flat plate will be
placed in the jig Refer to figure bellow figure
4.2.3.3.8. The pieces will be tacked together and turned over so the bottom
can be tacked together.
4.2.3.3.9. The tacked piece will be removed and fully welded with a 3mm
weld all round.
4.2.3.3.10. The same process from 3.3.1 to 3.3.5 will be done for the 30 x
250mm flat plate.



Lendell Beaumont

30
4.2.4 Drive Shaft

4.2.4.1. Shaft Requirements

The shaft will need to withstand shear stress caused by the twisting of the
shaft as well as circumferential stress
Must support the weight of all five blades
The material selected needs to be corrosion protected
The material needs to be light and rigid

4.2.4.2. Results

The shaft would be made from a 40 mm nominal bore hollow pipe. The cleats
that holds the blade support to the shaft will be made of a 60 nominal bore
hollow pipe and the cleats will be made from 6 x 30mm flat bar.

The maximum Yield strength for steel is 250MPa, Ultimate strength is 400MPa
The maximum torque created by the blades would be 54NM

From the calculation done on the circumferential stress the maximum shear would
be 17.5KPa. When compare to the maximum value of 250MPa the shaft is
suitable for the job.

The shaft would be 1200mm long. The blades on the shaft would be spaced at 72
degree intervals as this allows the blades to receive maximum wind and there will
always be a blade facing the direction of the wind.


4.2.4.3. Manufacturing Process

Due to the length and the arrangement of the cleats it was neaseary to fabricate
each piece separate and then do an assembly of the entire component at the end.

4.2.4.3.1. The flat bar for the cleats are supplied in 6m lengths.
Therefore each length will be cut into 3mm length to make it easy
to handle
4.2.4.3.2. Each cleat is 30 x 50mm
4.2.4.3.3. 2 Holes will be punched into each cleat as per fabrication
drawing
4.2.4.3.4. The cleats will then be cut into 50mm lengths
4.2.4.3.5. A 60mm nominal bore hollow pipe will be cut into 50mm
length with the use of a band saw for accuracy
4.2.4.3.6. The 50mm nominal bore punch will be placed into a jig
4.2.4.3.7. The five cleats will be placed into the jig
4.2.4.3.8. All components will be tacked
Lendell Beaumont

31
4.2.4.3.9. The components will be turned over and tacked before
removing and full welded
4.2.4.3.10. A second jig will hold the completed components after
welding
4.2.4.3.11. The cleats will be equally spaced and the 50mm nominal
bore pipe will be slide in
4.2.4.3.12. The pieces will be tacked together before removed and
fully welded







Lendell Beaumont

32
4.2.5. Coupling

4.2.5.1. Requirements

Needs to transfer the shaft torque to the gearbox shaft
Need to light but strong and rigid
Need to with stand shearing


4.2.5.2. Results

The coupling was designed around the shaft diameter.
The maximum torque created by the rotating shaft was 104Nm
When the calculation was done to find the maximum torque the coupling can with
stand. It was found that the coupling that was design around the shaft diameter
can with stand a maximum torque of 375Nm that 3 time greater than the 104Nm
created by the shaft.
Therefore the coupling will work.
The coupling also acts a support for the blade assembly.


4.2.5.3. Manufacturing Process

4.2.5.3.1. The coupling will be machined from a solid piece of of
steel so there are no joints and welds.
4.2.5.3.2. This will make the coupling stronger and will reduce shear.
4.2.5.3.3. The coupling will then be welded to the 40mm nominal
bore shaft to complete the shaft assembly.







Lendell Beaumont

33
4.2.9. Gear Box
A gear box is important in the turbine because it changes the axis of rotation from the
rotor to the generator as well as providing the required gear ratio for the generator.
The gear ratio was decided upon the design specifications of the generator and the
available torque and speeds developed by the turbine blades trough the rotor.
The gears itself, were calculated by selecting the teeth numbers giving the required gear
ratio. All the necessary calculations were done using Solid Edge input parameter based
on:
The gearbox is to be floor mounted and serves as support for the rotor shaft. For this
reason, the material of the gearbox casing has to be capable to withstand the stresses
caused by the wind blowing the blades.
4.2.10 Generator
The generator is a tri-phase star connected ac output. This configuration allows the
generator to start producing electricity at low speeds, making it an advantage for the wind
turbine. The current supplied by the generator is DC, meaning that there is a rectifier
converting the tree-phase AC from the windings to single phase DC output.
The generator used is rated 1800 watts at 450rmp. Due to the nature of the wind speed
inside the tunnel, an estimated torque of 8.1Nm is expected from the rotor. The gearbox,
with its 2,8 gear ratio suggests that the generator will be easily supplied with the rated
speed because the average rotor speed is 573rpm.

4.2.11 Charge Controller
Charge controller is a device that limits the input of current from the generator to charge
the batteries. Although the current has to go through the battery charger before going to
the battery, it allows the battery charge not overcharge the batteries by limiting current
going to it.

4.2.12Battery Charger
For a system voltage 48V and battery capacity of 52AH, 6A battery charger was selected
because it is common practice to charge batteries with only 10% of its amp hour capacity.

4.2.13 Inverter
Inverters convert DC power to AC. At the same time they change the voltage stored in
the battery system to a more suitable AC voltage which is the type of power most tunnel
equipment use.
For the battery bank used, a 48VDC to 220VAC at pure sine wave inverter is to be used
for low voltage system supply.
Lower power inverters are cheaper. Suitable inverter power should be selected once the
load power requirement is identified. The 300w is suitable for the project because most
sensitive equipment such as computers monitors and sensors run on low power.


34



Fig: Grid tie System example
















D
C
Generat
or
Utility Grid
Battery
Charger
Grid Tie
Inverter
Battery Bank Critical Load
A
C
AC
Load

35
5 Calculations

5.1 Speed Bumps

5.1.1. Pipe Stress Calculations

Maximum tangential stress at the inner surface of the pipe:

t (max)
=
2 2
2 2
) ( ) (
] ) ( ) [(
i o
i o
r r
r r p

+
p = Internal fluid pressure in the pipe(MPa)
=
2 2
2 2
) 8 ( ) 10 (
] ) 8 ( ) 10 [( 4 . 5

+
r
i
= Inner radius of the pipe
= 24.6MPa r
o
= Outer radius of the pipe.

Minimum tangential stress at the outer surface of the pipe

t(min)
=
2 2
2
) ( ) (
) ( 2
i o
i
r r
r p


=
2 2
2
) 8 ( ) 10 (
] ) 8 )( 4 . 5 ( 2


= 19.2MPa

Ultimate tensile stress is 400MPa and using a factor of safety 3:1, the allowable tensile
strength is:

w
=
fety factorofsa
t
o

=
3
10 400
6


= 66.67MPa

The minimum yield strength of mild steel is 250N/mm
2
which is equivalent to 250Mpa.
Since the tensile strength in the pipe (24.6MPa) is less than the yield strength and the
allowable tensile strength, the pipe will not fail.

Ref: www.csmsteel.com
A Textbook of Machine Design by R.S.KHURMI AND J.K.GUPTA (pdf)









Shazeem Tulsi

36

5.1.2 Reynolds Number and Bernoullis Equation

A 20mm diameter pipe was chosen:

Since Q =A.V Q= volumetric flow rate (m
3
/s)
V =
A
Q
A= Area (mm
2
)
V =
2 3
) 10 20 (
4
0084 . 0

t
V= Velocity (m/s)

= 26.73m/s



Re=
u
vd
Re=Reynolds Number

But u = v x v- kinematic viscosity (cSt)
= (25 x 10
-6
) (870) - density (kg/m
3
)
= 0.02175 kg/ms u- dynamic viscosity (kg/ms)

Therefore:
Re =
) 02175 . 0 (
) 10 20 )( 73 . 26 )( 870 (
3


= 21384
= 2.1384 x 10
4


Since using commercial steel pipe:
c= 4.5 x 10
-5
c- surface roughness (mm)
(Moody Diagram)
Relative roughness =
d
c

=
3
5
10 20
10 5 . 4



= 2.25 x 10
-3






Shazeem Tulsi

37

Using the Moody Diagram, figure 1.7:

Friction factor (f) = 0.013















Shazeem Tulsi

38
Now Bernoullis principle could be used:

l f
h h Z
g
V
g
P
Z
g
V
g
P
+ + + + = + +
2
2
2 2
1
2
1 1
2 2


P- Pressure (Pa)
- Density (kg/m
3
)
V- Velocity (m/s)
Z- Height (m)
H
f
- frictional losses (m)
H
l
- other losses (m)
The Darcy- Weisbach Equation:

H
f
=
gd
flv
2
4
2

And:
H
l
=
g
kv
2
2
k- loss coefficient
R- centre line radius
d- inside diameter

Table 1 K values for pipe bends and elbows
90 Bends
d
R

K
1.0 0.4
1.5 0.32
2.0 0.27
3.0 0.22
4.0 0.20

Table 2 K values of valves
Type K
Foot valve with strainer 2.5
Globe valve completely open 10
Angle valve completely open 5
One way valve swing type 2.5
ball type 70
Gate valve
Completely open 0.19
open 1.15
open 5.6
open 24
Shazeem Tulsi

39
From point 1 to 2:


l f
h h Z
g
V
g
P
Z
g
V
g
P
+ + + + = + +
2
2
2 2
1
2
1 1
2 2


) 81 . 9 ( 2
) 73 . 26 ( 27 . 0
) 81 . 9 ( 2
) 73 . 26 )( 5 . 2 (
) 10 20 )( 81 . 9 ( 2
) 73 . 26 )( 25 . 2 )( 013 . 0 ( 4
) 81 . 9 ( 2
73 . 26
) 25 . 0 (
) 81 . 9 ( 2
73 . 26
) 81 . 9 )( 870 (
10 4 . 5
2 2
3
2 2
2
2 6
+ +

+ + = + +

g
P


P
2
= 2.723MPa

Note: h
l
is the loss due to a 90 bend and due to an isolation valve which is the swing
type check valve.

From Point 2 to 3:

l f
h h Z
g
V
g
P
Z
g
V
g
P
+ + + + = + +
3
2
3 3
2
2
2 2
2 2


) 81 . 9 ( 2
) 5 . 25 )( 5 . 2 (
) 10 20 )( 81 . 9 ( 2
) 5 . 25 )( 10 800 )( 013 . 0 ( 4
) 81 . 9 ( 2
5 . 25
) 81 . 9 ( 2
5 . 25
) 81 . 9 )( 870 (
10 12 . 5
2
3
2 3 2
3
2 6
+

+ + = +

g
P



P
3
= 3.82MPa

Since:
V=
60
2 N t
N- number of revolutions (rev/min)

N =
t 2
60 V

=
t 2
) 60 )( 5 . 25 (

= 243.51 rev/min

Therefore, the orifice will have to increase the velocity in order to gain a constant 250
rev/min as needed by the motor specifications.
V =
60
2 N t
V needed = 26.18 25.5
=
60
) 250 ( 2t
=0.68 m/s
= 26.18 m/s


Shazeem Tulsi

40
From Point 3 to 4:

l f
h h Z
g
V
g
P
Z
g
V
g
P
+ + + + = + +
4
2
4 4
3
2
3 3
2 2


) 10 20 )( 81 . 9 ( 2
) 18 . 26 )( 10 100 )( 013 . 0 ( 4
) 81 . 9 ( 2
18 . 26
) 81 . 9 ( 2
18 . 26
) 81 . 9 )( 870 (
10 82 . 3
3
2 3 2
4
2 6

+ + = +

g
P



P
4
= 3.74MPa


0.1MPa = 1 Bar
Therefore, 3.74MPa = 37.4Bar

Q = A. V lpm- litres per minute
= ) 18 . 26 ].( ) 10 20 (
4
[
2 3

t

= 0.00822m
3
/s
= 493.2 lpm


























Shazeem Tulsi

41

5.1.3Motor Equations

Torque =
rpm
pressure flow 91 . 15
Torque (Nm)
=
250
91 . 15 4 . 37 2 . 493
Flow (lpm)
= 1173.88Nm Pressure (Bar)

Power =
9543
rpm torque

=
9543
250 88 . 1173

= 30.75KW

Displacement =
rpm
flow 1000

=
250
1000 2 . 493

= 1972.8cm
3
/rev

The motor will meet specifications of the system.























Shazeem Tulsi

42
5.1.4 Orifice Design

From above calculations the velocity needed from the orifice 0.68m/s.

Pressure drop = 3.82MPa 3.74MPa
= 0.08MPa
Therefore H =
g
P


=
) 81 . 9 )( 870 (
10 08 . 0
6


= 9.37m of Oil
Qact = A.V
=
4
t
(20 x 10
-3
)
2
(0.68)
= 2.136 x 10
-4
m
3
/s



Since Qact = C
d
A
1
1 ) (
2
2
0
1

A
A
gh

= (0.6)(
4
t
(20 x 10
-3
)
2
)
1 )
10 20
(
) 3 . 9 ( 2
2
0
3


A
g

Therefore d
o
= 5.6mm


















Shazeem Tulsi

43
5.1.5Tank Calculations

Since displacement =1972.8cm
3
/rev and N=250rpm
Tank volume = 1972.8 x 250
= 493200 cm
3

= 493.2 l

Due to standards, tank volume= 630 l

Volume =
1000
H W L
L, W, H (cm)
=
1000
68 90 150

= 918 l

The tank would be subjected to standard pressure.






























Shazeem Tulsi

44
5.1.6 Design of oval flange pipe joint



The force trying to separate the two flanges has to be resisted by the stress produced in
the bolts

It is important to use the outside diameter of packing and it is assumed that the packing is
5mm.
Therefore, D
1
= 20+ 2(5)=30mm

The force separating the two flanges due to fluid pressure is given by:

F =
4
t
(D
1
)
2
p
=
4
t
(30)
2
(5.4)
= 3817.04N

Since two bolts will be used the force in each bolt is:
F
b
=
2
04 . 3817

= 1908.52N




We also know that the load in the bolt:
F
b =
4
t
(d
c
)
2

tb
where
tb
is the maximum tensile stress in the bolt
1908.52 =
4
t
(d
c
)
2
(100)
d
c
= 5.11 say 6mm
Shazeem Tulsi

45

Nominal diameter of bolts:

d =
84 . 0
c
d

=
84 . 0
6

= 7.14 say 8mm

Outer diameter of the flange:

Do =D + 2t + 4.6 d
= 20 + 2 4 + 4.6 8
=64.8 say 65 mm

Pitch circle diameter of the bolts:

Dp =Do (3t + 20 mm)
= 65 (3 4 + 20)
= 33 mm


Tf from diagram


Ref: A Textbook of Machine Design by R.S.KHURMI AND J.K.GUPTA (pdf)




















Shazeem Tulsi

46
5.2.3. Piston Cylinder calculations

V
olume
= P
iston

troke

=


= 128 cm
3

V
retraction
= V
ext
V
rod

= 128

)
= 82 cm
3
V
total
=

)
troke

=

) 0.065
=209.3 cm
3



F2 F1

F3 0.5m 0.6 m 0.7m


1.8 m

The motor vehicle is traveling in the direction as shown by the above arrow
Consider the four small shapes as piston cylinders. The maximum speed for the hump is
40km/h and the minimum weight that will push down the cylinder is 1000 kg and since
the fluid level is very small the fluid resistance to flow value can be neglected.

=8.2 and

=6.2

1) F
orce1
=

()

=9911 N

2) F
orce2
= mg
=
= 9810 N

3) F
orce3
=

()

= 9868 N

4) V
elocity
=


= 11.1 m/s
Zamani Bhulose

47
Assumptions: the motor vehicle velocity will be constant when it crosses
the hump

5) The time taken for the car to press down the piston rod can be calculated by:
t
1
=


= 0.063 sec

t
2
=


= 0.0541 sec

t
3
=


=0.045 sec
100mm diameter of a cylinder was selected

The pressure in the cylinder can be calculated

1) P
1
=


= 5.04MPa


2) P
2
=


= 5MPa

3) P
3
=


= 5.03MPa

Flow rate from each piston must be calculated, the volume for the all cylinders is the
same and the fluid level is 75mm from the bottom of the cylinder.

V
olume
=Area
=


= 128

m
4
So using the calculated time, flow rate can be found

1) Q
1
=


=0.002

/s
Zamani Bhulose

48

2) Q
2
=


=0.00236

/s
3) Q
3
=


= 0.0028

/s

65mm pipe

Flow rate in the cylinder = flow rate in the pipe


1) V
pipe
=


= 2 m/s

2) V
pipe2
=


=2.7 m/s

3) V
pipe3
=


= 3.2 m/s

Using Bernoullis equation, pressure in the pipe can be calculated. It a 20mm diameter
mild steel pipe which is 400mm long and friction factor is found to be 0.001. The specific
gravity for mineral oil is 870 kg/m
3
.

Since the height difference and V
1
is very small. It can be negligible.


1)



P
2
=16.096MPa

Although there were valves but still the pressure did not change that much


Zamani Bhulose

49
5.2.3. Structural analysis

Using the total weight of a fully loaded 84 sitter bus and plus the account for an overload,
the maximum force of 200KN was used for testing the structure.
Using Appendix a W150 18 I beam column was selected
I
xx
=9.19

m
4


To solve for bending moment at the centre of the beam, let assume there is a hinge at the
centre, i.e. the bending moment will equal to zero.

Since the frame is symmetrical, one half of a frame can be considered.

V
A
=V
B
=99.9KN

=0
H
A
0.653 +V
A
0.9 q 0.9

=0
H
A
=68.8KN=H
B

Using modified Castiglianos method, bending moment at the centre can be found.
By applying unit force at C
The horizontal reactions can be calculated
V
A
=V
C
=

=0

0.9 + H
c
0.653 =0
H
C
=0.69KN=H
A
From the table W150 and W200 Wide flange columns were selected, which
gives moment of inertia for the both columns as, 20.4mm
4
and 9.19mm
4
respectively.

EI
1
=

4.284


EI
2
=210

1.9299


Using modified castiglianos numerical method, deflection at the centre can be found

d
x
=2*

)+
=0.007mm

Zamani Bhulose

50
Since deflection is equal to bending moment over stiffness, the bending moment at the
centre is calculated.

BM
B
=17.89KNm
To check whether the structure wont fail, the moment of resistance must be more than
the bending moment at the centre. Moment resistance equation=0.9

, where

e
=


The yield stress is 250MPa for mild steel.
Since the I beam column cross section is symmetrical

is at the centre which is =75mm



e
=


Using equation for moment resistance
M
resistance
=0.9


=27KNm
This is greater than 17.89KNm therefore the structure wont fail

Calculating the compression stress


= 149MPa
Since this is less than the yield stress for mild steel the structure wont break.
The maximum stress at the cross section for the I beam column can be calculated using
the following formula.

max
=


Q=A= (b


= (90

)
= 496

m
3
I=6.293

m
4

max
=


= 197MPa
Using equations (5-48b) from (Gere, 5
th
edition, p.g. 360) minimum shear stress is
calculated as follows.

)
=


= 159MPa



The shear force in the web is calculated as follows
V
web
=

)

51
=

( )
= 184.3KN
The beam resistance factor (B
RF)
is calculated
B
RF
=


= 92% this is good


= 200MPa
The structure wont fail since the shear stress in web is 1.5% more than the maximum
shear stress.


Moment of inertia= (


=(

( )


= 23.048

m
4




























Zamani Bhulose

52

5.2.3. Spring Calculation
Table 1.2

From table 1.2, Chrome-vanadium material spring that has 8mm spring wire diameter and
60mm mean diameter is selected.
Table 1.2

From table 1.3, modulus of elasticity and rigidity is found to be 203.4 and 77.2 GPa. The
total number of turns is 11.
Figure 3
www.lesjoforsab.com,06April2012





1) S
ut
=


= 1.4227 GPa
2)
allowable
= 0.45(S
ut
)
Zamani Bhulose

53
= 1.4227 0.45
= 619.5 MPa
3) Spring Force =


= 2075.98 N
4) Solid length (L
s
) = N
a


= 9
= 72 mm

5) Spring constant(K) =


= 16.6 KN/m

6) Deflection of spring(Y) =


= 125 mm
7) Original spring length(L
o
) = Y+L
s


= 125
= 197 mm
8) Pitch =


= 21 mm


9) Maximum outside diameter(D)=D+d
= 60+8
= 68 mm

For stability L
0
<

*
()

+

If both the ends of the spring are hinged than =1
If the selected is 1 than the value found is 159 mm and since L
o
=197mm the
spring will buckle since L
0
must be < than 159mm.
So if =0.707 using the above equation
L
0
<

()



= 224 mm since L
o
<224 this means that the spring is stable. Hence for it
to not buckle it must be hinged and fixed in one side.
Zamani Bhulose

54

Zamani Bhulose

55
5.2.3Accumulator sizing
The maximum pressure (P
3
) in the system is 16.096 MPa and the minimum pressure (P
2
)
12.8 Mpa and nitrogen gas is used, i.e. n=1.4
n =


=1.26
I. From the table1.1 the value of n which is 1.26 is selected in this case 1.25
was selected.
II. Then since the oil to be discharge is known, which is 0.39 litres, than from the
table the value which is 0.39 is selected, in this case 0.39 litres was found and
moving vertical upwards 4 litre size accumulator was found.

Table 1.4

www.olaerfawcettchristie.co.uk
P
1
- Is the gas pre-charge pressure.
P
2
- Is minimum working pressure in the system.
P3- Is the maximum working pressure in the system.
P
1
= 0.9P
min

=0.9
= 11.52 Mpa
To check for the life of the Bladder accumulator


>4

=1.26, which is less than four thus this is suitable

> 5

= 1.4, which is less than five thus this is suitable


Figure shows the discharge of the accumulator
Zamani Bhulose

56

www.groveengineering.com

Assumptions: there is no change in temperature between point 1 and point 3 (Isothermal
compression)
P
1
v
1
=P
3
V
3

V
3
=


= 2.86 litres
Assumptions: there is an adiabatic expansion process between point 2 and point 3
P
3
V
3
n
=P
2
V
2
n
V
2
= (


= (


= 3.4 litres

Zamani Bhulose

57
Oil filters
Oil filters will be required to remove unwanted contaminants from oil, since the system
will be exposed to dirt. Sensitive components like hydraulic motors require clean oil and
this can increase the life of all other equipments in the hydraulic system.
Types of filters
Rejected
1) Centrifugal filter
This type of filter uses the rotation of a rotor to remove unwanted impurities from
the oil although they are most efficient but the rotor needs to rotate very fast so
that it can contaminants can be removed.
Selected
1) Bypass filter
In this type of oil filter oil is filtered in small segments, this means most oil goes
straight to the tank and the small proportion of oil is sent through the filter this
reduces the oil that becomes staggered in the filter and it also increases the life of
the filter, hence the maintenance cost is reduced.
Zamani Bhulose

58
Traffic Tunnel

5.2.1Blade
The blade has two supports at either end to reduce the bending.
5.2.1.1Blade deflection




When changing fiberglass to Aluminum you multiply it by



I of composite material

)]
(







Lendell Beaumont

59


22.
Aluminum
@ 0.25 deflection



Steel
@ 0.25m deflection



Fiberglass
@ 0.25m deflection



Composite Material (aluminum and fiberglass)
@ 0.25m deflection




5.2.1.2 Shear stress created in the blade










Lendell Beaumont

60
5.2.3. Connecting Arm

On the x-axis there will be a moment caused by the blade weight of 0.42Nm
and on the y-axis a moment of 8.1Nm caused by the wind force.
First step was to calculate the second moment of inertia





3mm 6mm

180.93MPa 45.47MPa

-179MPa -44.5MPa

179MPa 44.5MPa

-181MPa -45.5MPa
3mm 6mm


Lendell Beaumont

61
5.2.3 Drive Shaft

The angular velocity of the shaft is 573Rpm as calculated in the blade design.


Circumferential Stress




Max torque the shaft can with stand
D = 50mm d = 40mm Modulus of elasticity = 80GPa

(


























Lendell Beaumont

62
5.2.4 Coupling


The shaft diameter is d = 50mm

Outside diameter




Lendell Beaumont

63
5.2.5 Spur gear selection

A gear box is important in the turbine because it changes the axis of rotation from the
rotor to the generator as well as providing the required gear ratio for the generator.
The gear ratio was decided upon the design specifications of the generator and the
available torque and speeds developed by the turbine blades trough the rotor.
The gears itself, were calculated by selecting the teeth numbers giving the required gear
ratio. All the necessary calculations were done using Solid Edge input parameter based
on:
- Simple bending stress
- Material strength at minimum factor of safety
- Based on standards
- Load based on torque
The gearbox is to be floor mounted and serves as support for the rotor shaft. For this
reason, the material of the gearbox casing has to be capable to withstand the stresses
caused by the wind blowing the blades. The gearbox is material is aluminum because it
aluminum made for gearbox application makes lighter and strong gearboxes.

Desired gear ratio is determined by torque from rotor shaft and generator starting torque

, therefore:




() , teeths



, chosen. Factor of safety for both pinion and gear are high for the
face width chosen, therefore it can be used.


64

65

66




















Afonso Luis

67
5.2.6 Battery Bank Sizing
Battery Bank Sizing
The Objective is to design a power supply system to provide at least 10% of running load
of tunnel to help reduce costs bringing benefits to the environment as well.
Taking 10% of the total 17.3 Kw load of The Waterval Boven tunnel (previously the
NZASM tunnel) located just outside Waterval Boven on the N4, the battery bank for the
system is calculated.
Step Process Calculation
1 Total daily use in Watt-hours Wh 17.3 KW x10% x 24h = 1730
Wh/day
2 Identify Days of Autonomy (backup days);
multiply Wh/day by this factor.
0.67 Days of Autonomy:
1730 x 0.67 = 1159.1 Wh
3 Depth of Discharge (DoD) in percentage 50% DoD:
1159.1 / 0.5 = 2318.2 Wh
4 Minimum Amp-hour (Ah) capacity of battery
bank.
2318.2 Wh/48V = 48.3 Ah

The autonomy of 0.67 (16/24) was chosen because the turbines will be producing
electricity on a daily basis, but for an estimated period of 10 to 12 hours When the traffic
is lowest (8:00 PM to 8:00A M) not much energy will be produced. The battery is the
required to handle the load for 16 hours (4 hours more than the non-charging period).
Although the battery is deep cycle type, a 50% depth of discharge is advisable for long
life. Low temperature affects the battery charging capacity and is not a reason to worry in
most of South African territory given the specification of the battery from the
manufacturer. For this reason temperature effect on the batteries was left out in the
calculation. High temperature however, is a factor that reduces the life of the batteries.

Number of batteries needed:


The chosen battery voltage is 12 volts, therefore:



Therefore it needs 8 batteries to build a system to store 1.73 watts of power for 12 hours,
being 2 strings of batteries connected in parallel and 4 batteries in each string.








Afonso Luis

68



Fig: System sizing estimator example (at
http://www.freesunpower.com/battery_designer.php)




























Afonso Luis

69
Maintenance

Speed bumps

Regular maintenance on system components will be required. All components have been
chosen such that they have high levels of endurance. The oil will be passed through a
filter therefore removing impurities and can be used for many cycles within the system.
Effect of ageing on pipes
Lumps of rust against inner walls of steel pipes are caused by corrosion. Therefore pipe
surfaces are rough and the effective cross sectional area of pipes are reduced. (Ref5)

Piping

Vapour pressure and Cavitation

When pressure in the fluid drops below vapour pressure and causes heating of the liquid,
bubbles are formed. When the liquid and bubbles move to a region of high pressure, the
bubbles collapse and form liquid once again. This causes small shock wave which is
caused by condensation has a greater effect on local stresses (MPa) on the surface of
component parts, thus causing metal fatigue and therefore erosion. These affects leads to
decrease in the efficiency of components and the entire system. (ref 6)

For the system it was important to choose a pipe diameter which would allow for
maximum flow and thus maximum pressure to be transmitted from the pistons through to
the hydraulic motor. However the pipe diameter should also be able to handle high
pressures and flow and not break due to these constraints. Initially a 16mm diameter pipe
was chosen but was changed due to these stresses to a 20 mm diameter pipe


















Shazmeen Tulsi

70


Traffic tunnels

Gearbox Installation

For the gearbox to be installed it is recommended that the foundation for it is appropriate.
The ground inside the tunnel is made of concrete, therefore screws can be attached to the
ground so that nuts are used to tight generator and gearbox support.
The whole system to be installed next to the road will be divided into 3 main
components: rotor shaft with its blades, gearbox and generator. Necessary bolts, nuts will
and circlips will be used to assembly it on site. From there cabling will take power
generated to the Battery bank storage place where other equipment will also be placed.

Maintenance

Given the nature of the location where the turbine is to be installed it is essential for the
system to be easy to assemble install and maintain to avoid long time exposure of
technicians to traffic accidents. Although safety measures for those working on the
installation can be provided, it is important to notice that traffic should not be disrupted
for very long time.
For reasons mentioned above, parts were designed for easy assembly and long life, by
reducing the complexity of parts to be assembled by:
- reducing the number of bolts and nuts to be tightened
- selecting materials resistant to corrosion
- choosing surface polished gears to reduce wear
- choosing long service lubrication method

. 6. Safety

Standard safety protocol shall be adhered to. The system may only be accessed by
selected company personnel therefore restricted access.











Afonso luis


71
7. Costing

7.1 Speed Bumps

QUANTITY COMPONENT SUPPLIER MODEL
NUMBER
UNIT
COST
SUB
TOTAL
1 Hydraulic Motor BMG
Hydraulics
HMB 100 R10000.00 R10000.00
4 20 x2.5mm
Hydraulic tube
6m
BMG
Hydraulics
R38.40p/m R921.60
2 RHD Check
Valve
BMG
Hydraulics
R396.00 R792.00
12 HP Full Bore
Valve
BMG
Hydraulics
BKH 20S R306.00 R3672.00
1 Elbow Adapter BMG
Hydraulics
W20S R60.00 R60.00
1 0-250Bar
Pressure Gauge
BMG
Hydraulics
R485.00 R485.00
1 Pressure Switch
12-150Bar
BMG
Hydraulics
IPH-150 R455.00 R455.00
600l Mineral Oil Selona White
Mineral Oil
R17.65/kg R10590.00






















Shazmeen Tulsi

72

7.2 Traffic Tunnel

Cost for one Blade and shaft assembly
Bill of Quantity

Thickness Size Qty required Rate Total
3mm 2500x1500
3mm 30mm 5300mm R 18.6 R 98.58
6mm 30mm 1000mm R 21.78 R 21.78
pipe 40NB 1200mm R 100 R 120.00
pipe 50NB 150mm R 124 R 18.60
pipe 15NB 3750 mm R 50 R 187.50
Grand Total R 446.46

Labor

Labor supplied by SFUNDELE ENGINEERING CC

Skill Qty Time Rate Total
Boiler Maker 1 2 R 205 R 410
Welder 2 2 R 300 R 1200
Semi Skill 1 2 R 150 R 300
Grand Total R 1910

There for to fabricate a complete blade assembly will cost R 2356.46


















Afonso Luis


73
The main components of the system are
- Generator model GL-PMG-1800 PMG supplied by Ginlong Technologies, sold
by Green Joule.

Fig: Generator full specification (available at http://www.ginlong.com/wind-turbine-
pmg-pma-permanent-magnet-generator-alternator-GL-PMG-1800.htm)











74
- Batteries : GP12260 12V 26Ah Battery

Cells Per Unit 6
Voltage Per Unit 12 V
Capacity 26 Ah at 20hr-rate to 1.75V per cell @ 25C (77F)
Weight (kg) Approx. 8.45 kg. (18.63 lbs.)
Maximum Discharge
current (A)
350 A (5sec.)
Internal Resistance
Approx.
Approx. 11 m
Operating Temperature
Range
Discharge-15~50(5F~122F)
Charge-15~40(5F~104F)
Storage-15~40(5F~104F)
Nominal Operating
Temperature Range
25C 3C (77F 5F)
Float charging voltage 13.5 to 13.8 VDC/unit Average at 25C (77F)
Recommended Maximum
Charging current limit
7.8 A
Equalization and Cycle
Service
14.4 to 15.0 VDC/unit Average at 25C (77F)
Self-Discharge
It should be more than 75% of the capacity that before storage after stocked for 6
months at ambient temp. 25
Terminal B1/B3/B3B-L terminal or Recessed type to accept M5 bolt

Table: Specifications (available at http://www.csb-
battery.com/english/01_product/02_detail.php?fid=5&pid=15)

- Battery Charger : 300W, BCxx-300 model available at
http://www.dcpowersa.co.za
- Inverter: IPS-5kW-48 model pure sine wave (5KW 48VDC to 220VAC).
Available at Carima product catalog
(http://www.carima.co.za/sites/default/files/pricelist_solar_20120423.pdf)


Equipent / Part
Unit Price
(R)
Quantity Total
Battery 570 80 45600
Inverter 8333.33 10 83333.3
Battery Charger 781.52 10 7815.2
Generator 18000 10 180000
Total 316748.5


75
PAYBACK PERIOD




CONCLUSION AND RECOMMENDATION











8. References

1- www.enginneringnews.co.za/article/february-power-consumption

2-Team 7- Dailhousie University, Department of Mechanical Enginnering

3- Engineer handbook

4- J.E Shigley
- C.R Mischke

5- Application of Fluid Mechanics Part 1
C.F Meyer

6-Application of Fluid Mechanics Part 2
C.F Meyer


For Traffic Tunnels

Formulae came from:

Mechanics of materials
Seventh edition
SI Edition
James M. Gere
Barry J. Goodno
Publisher : CENGAGE Learning


76



Precise referencing will be done in final report

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