CHAPTER: 1

INTRODUCTION
 1.1 Motivation

Today more than 80 per cent of the world’s electric power production comes
from fossil-fuelled plants.Future energy supply projections suggest that there will be
problems in matching supply and demand in the next century. Furthermore, since the
cost of primary energy will almost certainly rise, alternative forms of energy conversion
must obviously be investigated and developed as their supplementary or insurance
technologies.
Power generation in India today is mainly from hydroelectric and thermal
power plants. The present total installed capacity hardly meets the grid demand.
Uncertainty of the monsoon and problems of coal transport put a strong limitation on
expansion of present generation capacity. However, the increase in standard of living
and rapid industrial growth necessitates a high rate of growth of power supply. The
price of oil continues to be high in India. The present contribution of power generation
from nuclear plants is small, and the uncertainty in the protective measures against all
environmental hazards of such plants indicates that development of renewable energy
sources is important for India. [1]
As the demand for electricity is forecasted to increase, there is an urgent need
to find new methods to extract electric energy from renewable sources. Hence, the need
for renewable energy is fast-becoming essential in today's world energy market. The
world needs a source of energy that will last longer than our limited supply of fossil
fuels. Pollution is also an issue, and many environmentalist groups are pushing toward
more "earth-friendly" energy sources. Renewable electric energy supply is today one of
the highest priorities in many parts of the world.
The Kyoto declaration 1997 and the last agreement at Marrakech 2002 are
significant proof of this. One important renewable energy source is ocean energy.
Ocean waves represent a vast unexplored source of renewable energy.
 Solar radiation, which sustains life on earth, is continuous and inexhaustible. It
has been estimated that about 1016W of solar energy reaches the earth. The ocean, which
covers nearly 71% of earth’s surface, acts as a natural collector of this energy. Thus, the
ocean has an enormous potential to supply energy in many different ways. The major
advantages of ocean energy are that it is renewable and continuous throughout the year,
is pollution free and has minimum health hazard. For remote islands, ocean energy will
be the most important form of alternative energy since it comes from the immediate
vicinity.
The incessant motion of the sea surface in the form of wind waves constitutes a
source of continuous energy. About 1.5% of the incoming energy from the sun is
converted to wind energy. Part of the energy from the winds is transferred to the sea
surface, resulting in generation of waves. This energy is carried to coastlines throughout
the world, where it is dissipated as the waves break. If this source can be tapped
properly and used economically, it can generate a sizeable portion of world energy
needs.
Extraction of energy from waves is more efficient than directly from wind, since
wave energy is concentrated through interaction of the wind and the free ocean surface.
The sea behaves like an immense energy collector whereby the wind energy, transferred
to the large sea surface, is stored as mechanical energy in waves. The inertia of waves
provides this short-time storage and partly smoothens the high variability of the wind
over time and space.
Wave energy has the potential to be a much larger resource than tidal power.
Unlike tidal current extraction, which works best in the small number of highly
favorable sites wave energy can be extracted in many places along a coastline as well as
offshore.
With the substantial resource potential, a wide variety of methods for
extracting energy has been developed. The different devices and systems not only
employ different techniques for “capturing” the wave energy, but also employ a large
variety of different methods for converting it to electricity (i.e., the “power take-off”
system).
 The above mentioned causes have thereby motivated our project i.e. ocean
wave energy conversion which is based on a float and pulley mechanism.

1.2 Ocean Wave Energy Conversion

Basic wave energy conversion can be stated as the force (or torque) produced
in a system by an incident wave causes relative motion between absorber and reaction
point, which acts directly coupled to electric generator. Block diagram representation of
the proposed wave energy conversion system is shown in fig.1.1 .It consists of energy
conversion device which converts ocean wave energy into mechanical or some useful
form of energy. Converted energy (in the form of mechanical shaft power) is again
converted into electrical energy by an electric generator. Generated energy is further
stored by using suitable storage device such as a battery.
Fig. 1.1 Block diagram representation of wave energy
Conversion system

Ocean wave energy is total sum of kinetic potential energy of moving water
blocks. Wave energy available at Indian Coasts is in the range of 5kW/m to 70kw/m.
Using this energy conversion device 1 kW energy can be easily extracted.

1.3 Overview of the Project

The Ocean wave energy conversion system is a real time project of Saraswati
College of Engineering. The system is less efficient and hence requires more research
for the wide scale application of this system in our country. India has a major potential
for harnessing energy from ocean; the coastline of India being 7515 km. Our project is a
part of this research that can make this system more efficient by testing this system in a
laboratory against various parameters.

The two important objectives of this project are-

1. Modelling of the ocean wave energy conversion system
2. Increase in efficiency of the system

The project is based on modeling of the following systems:-

1. Float system
2. Ocean wave simulation
3. Power transmission system
The scope of the system being vast, it has been divided into three sub-groups
based upon the above three modeling systems. Out of the above three sub-groups, our
group is responsible for the modeling of the power transmission system and increase
in efficiency of the same.
The power transmission system forms a very important part of the project.
The efficiency of the entire project is largely dependent on this system. This system
basically comprises of the rope and pulley system, the unidirectional gearbox, a
generator and a storage battery. The original project on the lines of which our project
is modeled consists of similar components except for the high speed gearbox and
uni-directional clutch. This is what makes our project different from the original work
which has been described in detail ahead.
CHAPTER: 2
LITERATURE
SURVEY
2.1 Wave Energy Physics

Fig. 2.1 Wave generation

Among different types of ocean waves, wind generated waves have the highest
energy concentration. Wind waves are derived from the winds as they blow across the
oceans. This energy transfer provides a natural storage of wind energy in the water near
the free surface. Once created, wind waves can travel thousands of kilometers with little
energy losses, unless they encounter head winds. Near the coastline, the wave energy
intensity decreases due to interaction with the seabed. Energy dissipation near shore can
be compensated by natural phenomena as refraction or reflection, leading to energy
concentration (“hot spots”).
 Fig 2.2 Forms of energy in ocean wave
Ocean waves encompass two forms of energy: the kinetic energy of the water
particles that in general follow circular paths; and the potential energy of elevated water
particles. On the average, the kinetic energy in a linear wave equals its potential energy.
The energy flux in a wave is proportional to the square of the amplitude and to the
period of the motion. The average power in long period, large amplitude waves
commonly exceeds 40-50 kW per meter width of oncoming wave. [5]

2.2 Wave Creation

Ocean waves are created by the wind. When the wind blows across a
smooth water surface, air particles from the wind grab the water molecules they touch.
The force or friction between the air and water stretches the water surface, resulting in
small ripples, known as capillary waves. Surface tension acts on these ripples to restore
the smooth surface and thereby waves are formed. As waves form, the surface becomes
rougher and it is easier for the wind to grip the roughened water surface and intensify
the waves. The highest part of the wave is called the crest and lowest part that is
depressed beneath the surface is called the trough. The overall vertical change in height
between the crest and the trough (= 2 x amplitude) is called the wave height. The
distance between two successive crests is the length of the wave or wavelength (L).
The time required for two successive crests or two successive troughs to pass a point in
space is called the period (T). The number of peaks (or troughs) that pass a fixed point
per second is the frequency.

Fig. 2.3 Nomenclature of a wave

The air moves faster at the wave crests (point A) than in the troughs (point B).
By the Bernoulli principle, this produces a pressure differential that tends to increase the
elevation difference between the crest and trough. The area over the ocean in which a
particular set of waves is developed depends on the size of the pressure fronts involved.
This area is called a “fetch.”

Fig.2.4 Wave creation

2.3 Wave Energy Formula

[4]
Ocean waves are random in nature. The power available in random sea is
expressed as
P= 0.55×H2×T
 Where,
H=significant wave height (defined as average of highest waves) in
meters
T=zero crossing period in seconds.

The above formula states that wave power is proportional to the wave period
and to the square of the wave height. When the significant wave height is given in
meters, and the wave period in seconds, the result is the wave power in kilowatts (kW)
per meter of wave front length. From the above relation for a significant height of 2m
and a zero crossing period of 7 sec, the power is 15w/m of wave front.

For a sinusoidal wave of height H, the average energy E stored on a horizontal

square metre of the water surface is:
E=KE×H2
Where,
kE = ρ g / 8 = 1.25 kW-s/m2
ρ = mass density of sea water ≈ 1020 kg/m3
g = acceleration of gravity » 9.8 m/s2
Half of this is potential energy due to the weight of the water lifted from wave
troughs to wave crests. The remaining half is kinetic energy due to the motion of the
water.
As the waves propagate, their energy is transported. The energy in the waves
travel with the group velocity cg. The individual waves travel faster - they are born on
the rear end of the group, and they die in the front end. On deep water this phase
velocity is twice, the group velocity.The energy transport velocity is the group velocity.
As a result, the wave energy flux, through a vertical plane of unit width perpendicular to
the wave propagation direction, is equal to:
P=E × Cg
 Where,
Cg = group velocity (m/s)
On deep water the group velocity is cg = g T/4π

2.4 Wave Power Generation Device

The combination of forces due to the gravity, sea surface tension and wind
intensity are the main factors of origin of sea waves. While we know that wave power is
more energy dense than wind power for a large percentage of the year, we still do not
know how to calculate the power available from a wave. This is important for the
design process of a wave energy convertor. First, the power and forces acting on the
device should be assessed, and then the device may be sized for the desired energy
output. [2]

The main components of the ocean wave energy conversion device are:-
1. Float system
2. Rope and pulley system
3. Power transmission system (uni-directional gearbox, generator)
 The wave energy conversion device consists of float, flexible ropes, pulleys,
unidirectional gearbox, counter weight, electric generator, storage battery and
supporting frame. Float and counter weight is connected to each other using flexible
rope. Rope is passed over pulley system as shown in fig.2.5, which shows weight of
float and bouncy force is balanced by counter weight. Counter weight is designed such
that float is always half immersed in the water. The float is displaced when an ocean
wave crest or trough strikes the float. When a wave crest strikes the float, it is raised
against the dead weight and this rotates the input shat of the generator on which a pulley
is mounted. When a wave trough appears, the float is lowered raising the dead weight
and thereby again rotating the input shaft of the generator.
Thus, the float is subjected to two types of movement, one is the horizontal
movement due to horizontal thrust and the second one is the vertical movement due to
the vertical thrust. Therefore, it is the prime requirement to measure these horizontal
and vertical movements of the float. By measuring the displacement of the float, we can
calculate the wave energy absorbed by the float by using the wave energy formula.
 Pulley system is further connected to a unidirectional gearbox through
couplings. The unidirectional gearbox converts the to and fro motion of shaft to one
direction motion which is the prime requirement for generation of electrical energy via
electrical generator. The generator is further connected to storage battery or it can be
directly connected to electrical supply transport system.

Fig.2.6 Pilot plant of ocean wave energy converter at Ratnagiri, Maharashtra

2.5 Float system

The float is one of the prime requirements of the ocean wave converter. The
float receives the energy in the form of waves. The float is displaced when an ocean
wave crest or trough strikes the float. When a wave crest strikes the float, it is raised
against the dead weight and this rotates the input shat of the generator on which a pulley
is mounted. When a wave trough appears, the float is lowered raising the dead weight
and thereby again rotating the input shaft of the generator. Thus, the float is subjected to
two types of movement, one is the horizontal movement due to horizontal thrust and the
second one is the vertical movement due to the vertical thrust. Hence, the selection of
best design and material for a float is essential.

BOUYANCE
FLOAT MASS VOLUME
FORCE

1.943 kg 2.4856 × 10-3 m³ -28.80 N

(approx) (approx) (approx)

1.856 kg 2.37356 × 10-3 m³ -37.16 N

(approx) (approx) (approx)

1.514kg 1.9363 × 10-3 m³ -38.11 N

(approx) (approx) (approx)

Table 2.1: Types of float designs & their parameters

2.6 Wave generation tank

The figure below shows the varios components of the wave generation tank
along with there dimensions:
 Fig.2.7 Dimensions and labelling of tank

Fig.2.8 Components of wave generation tank

Dimensions are as follows :
Length of tank : 6 feet
Width of tank : 2 feet
Height of tank : 2 feet
The wave generation tank used for the simulation is made of marine wood.

Why wood is selected as material?

1. It is light in weight hence easy for transportation.
 2. It is cheaper compared to metal and plastic since their fabrication cost is much
higher.
3. Wood is easy to craft compared to metal and plastic.
4. Modifications can be easily done on wood hence proves a better option for our
experiment.
5. Since marine wood is used there is no question of swelling of wood.

Components of tank .
➢ Piston giude:
• To guide the vertical motion of the piston
• To achieve the constraint motion of the piston so that there is no
deflection while applying force on water surface.
➢ Piston
• It is used to get a uniform pressure distribution on the water surface.
➢ Valve
• It acts as aone way valve.
• It is used to prevent the non-return motion of the water.
➢ Variable Inclined plate
• To vary the outlet discharge area of water from the water column.
• With the help of variable inclined plate, we can obtain different wave
height and wave length.
➢ Fixed angle plate
• It is adjusted at a fixed angle of 600 as obtained in the calculations.
• It directs the water coming from the water column.
• The forced water takes the profile of the fixed angle plate and comes out
as a wave.

➢ Variable sea shore angle plate

 • Its function is to minimize the back force of water striking thw tank
wall.
• To examine the effect of back force of water on the float at different sea
shore angle.

Components of Mechanism :
➢ Piston
➢ Connecting rod
➢ Crank
➢ Dead weight
➢ Bearing
➢ Handle

Fig.2.9 Mechanism of simulation tank

CHAPTER 3:
PROBLEM
DEFINITION
3.1 Scope of project

An ocean wave is a sum of a wave crest and a wave trough. The float is
displaced when an ocean wave crest or trough strikes the float. When a wave crest
strikes the float, it is raised against the dead weight which is connected to the other end
of the rope moving over the pulley. This movement of the rope along with the dead
weight rotates the pulley and thereby the shaft in a particular direction say anti-
clockwise .This rotates the input shat of the generator on which a pulley is mounted,
thereby producing electricity.
When a wave trough appears, the float is lowered raising the dead weight and
thereby again rotating the input shaft of the generator. Thus, in the ocean wave
converter, the input shaft on which the pulley is mounted rotates in both the direction.
However, for the continuous power generation at the generator a unidirectional motion
(rotation) of the output shaft is required. This problem gives a wide scope for our
project. This report mainly gives a solution to this problem. This can be achieved by
using a mechanism which converts the bi-directional motion of the shaft into uni-
directional motion. We have sought a solution by using a uni-directional gearbox
utilizing a chain and sprocket arrangement.
The Uni-directional gearbox converts bi-directional motion of a shaft in to
unidirectional motion of another shaft. It converts the alternative rotation into
continuous rotation with no significant loss in transmitted energy. This captured and
converted energy in the form of mechanical rotation could be used for further
utilization. This unidirectional gearbox is capable of converting any clockwise or anti-
clockwise directional rotation at its input shaft into continuous unidirectional rotation at
its output shaft. This process happens with no significant energy loss.
3.2 Concept of Uni-directional gearbox

Fig 3.1 Schematic of a Uni-direction gear box.

Construction:-
This type of unidirectional gearbox consists of sprockets and chain which
convert the bi-directional motion of the input shaft into a uni-directional motion, which
is the prime necessity in a generator.
components of a unidirectional gearbox
1. Sprocket (6 NOs.)
2. Chain (2 NOS.)
3. Shaft on which sprockets are mounted (4 NOS.)
4. Bearings (8 NOS.)
5. Side Plate (2 NOS.)

Fig.3.2 The working model of uni-directional gearbox

Working: -
1. On the input shaft are mounted the pulley and the sprocket between the bearings.
2. When the pulley rotates in anticlockwise direction sprocket 1, 3 &4 rotates in
the same direction as that of the pulley (i.e. anticlockwise direction).
3. However the other three sprocket i.e. 2, 2'& 4' rotates in the clockwise direction.
4. It should be noted that 2'& 4' always rotates in the clockwise direction. This is
due to the free wheel mechanism in the sprocket.
5. When the input shaft rotates in the anticlockwise direction the free wheel
mechanism start acting in the sprocket 4.
6. When the shaft rotates in the clockwise direction the free wheel mechanism start
acting in the sprocket 2.
7. This mechanism gives uni-directional motion to the output shaft which is
connected to the generator irrespective of the direction of input rotation.

CHAPTER: 4
DESIGN
CALCULATION
4.1 Shaft Design

Velocity of float=V= 0.5 m/s

Diameter of pulley= Dpulley= 0.052m
V = π DpulleyN60
N = 60×0.5π×0.052 =183.64 rpm

Torque, Mt= force on pulley× radius of pulley

=75 × 0.026
=1.95 N-m
Power, P = 2πNMt60
= 2π×183.45×1.9560 = 38W

Vertical and Horizontal Forces

Pulley at A
Weight of pulley = 2.34N
Weight of Dead wt. = 75 Cos 40=57.453N
Tension in rope = 75 Cos 40=57.453N
∴Vertical force on pulley
(FV) A = Wt. of pulley + Wt. of Dead weight.
+ Tension in rope
=2.34+ 57.34 + 57.453
∴ (FV) A =117.246 N

∴Horizontal force on pulley, (FH) A = 75 sin 40

 ∴ (FH) A =48.209 N

Sprocket at C

Weight of sprocket = 1.86 N

Diameter of sprocket=D sprocket = 65mm
TtTs= eμθ
TtTs=1.05 …………… µ very less=0.02θ=180o
( Tt – Ts) Dsprocket2 = Mt
(1.05Ts – Ts ) 652 = 1.95×103
Tt = 1200 N
Ts = 1260 N

Resultant tension, Tc = Tt + Ts
= 1260+1200
= 2460N
Vertical force on sprocket
(F V)C = Tc sin 40 + W Sprocket
=2460× Sin50 +1.86
(F V)C = 1583.117 N

Horizontal force on sprocket

(FH)C = TC cos40
= 2460 cos40

(FH)C = 1884.469 N

Table 4.1 : Horizontal & vertical forces on pulley & sprocket

Forces Pulley A Sprocket C

Horizontal (FH)A=48.209 N (FH)C=1884.469N
Vertical (FV)A=117.246N (FV)C=1583.117 N
 Fig 4.1 Vertical & horizontal bending moment diagram

Vertical Reaction
MB=0
117.246×36+VD ×103=(1583.117 ×33.5)

VD = 473.91 N

FV=0
117.246 + 1583.117 - 473.91 = VB
VB = 1226.453 N

Vertical Bending Moment

(MA)V = (MD) V = 0
(MB)V = 117.246 ×36 = 4220.856N-mm
(MC)V = (117.246× 69.5) – (1226.453× 33.5) = 32937.57 N-mm

Horizontal Reaction
MB=0
48.209 ×36+ HD ×103=1884.469 ×33.5

HD = 596 N

FV=0
48.209 + 1884.469 – 596 = HB
HB = 1336.678 N

Horizontal Bending Moment

(MA)H = (MD) H = 0
(MB)H = 48.209 ×36 = 1735.524 N-mm
(MC)H= (48.209 × 69.5) – (1336.678 ×33.5) = 41428.187 N-mm
Resultant Bending Moment
(Mb ) B = MBH2+ MBv2 = 4563.734 N-mm
(Mb)C = MCH2+ MCv2 = 52926.158 N-mm

Thus from BMD, the critical point is at point C

Mb= (Mb) C = 52926.158 N-mm
Mt =1.95×103 N-mm

Material Selection
Shaft material: - C-50………………………………….. P.S.G1.9[ 6 ]
σyt = 380 N/mm2

Allowable stress: -
σt = σytFOS = 95 N/mm2…………………..F.O.S = 4 (assume)
τ=0.5 σt …………………………… (as per Maximum Shear Stress Theory))
=47.5 N/mm2

Combined fatigue and shock load factor………………P.S.G7.21

( Kb , Kt - revolving shaft and assuming minor shock load factor)
Kb= 2, Kt = 1.5
Equivalent Bending Moment
(Mb)e= 12MbKb+(MbKb)2+(MtKt)2
= 12 52926.158×2+52926.158 ×22+1.95×103×1.52
= 105.872 ×103 N-mm

Equivalent twisting Moment

Te = (MbKb)2+(MtKt)2
= 52926.158 ×22+1.95×103×1.52
=105.892 ×103 N-mm

Diameter of shaft

1) Based on maximum normal stress

d = 332 Mbeπ (σt)
=332×105.872 ×103π × 95
d = 22.474mm

2) Based on maximum shear stress

d = 316 Te π ( τ)

= 316 × 105.892 ×103π × 47.5

d =22.475
Taking greater value
i.e. d =22.475

∴Standardizing the shaft diameter,

d = 25mm

Optimizing shaft design

Table 4.2:- Effect of variation in shaft dia. on various parameter
Hollow Hollow Hollow
Compone
Solid shaft shaft with shaft with shaft with
nt
I.D. = 10 I.D. = 12 I.D. = 13
Material C-50 C-50 C-50 C-50
 Area
0.016 0.021 0.022 0.022
[m2]
Volume -5 -5 7.9955 x
9.8574 x 10 8.5646x 10 7.6723 x 10-5
[m3] 10-5
Density
7860 7860 7860 7860
[Kg/m3]
Mass
0.775 0.673 0.628 0.603
[Kg]

Graph 4.1: Shaft dia. Vs Mass of shaft

We know that, hollow shaft are stronger per kg of material and they can be
forged on a mandrel, thus making the material more homogeneous than in case of
solid shaft. Therefore, instead of solid shaft for same strength, we can use hollow shaft
which will reduce material and overall system weight. This reduces the cost of the
system.
4.2 Bearing Selection

Load on bearing : For B

Radial load (Fr) = 1.226 KN
Axial load (Fa) =1.336 KN
For D
Radial load (Fr) = 0.473 KN
Axial load (Fa) =0.596 KN

Bearing speed : N=185rpm

Expected Life in hours : Lhr =17520
Probability of survival : P07= 93%
Temperature factor : Kt =1
Type of bearing : Ball bearing

Expected life of bearing in million revolutions (mr) for 93% probability of survival:

L07 = Lhr×N×60106
=17520×185×60/106
=194.47 mr
Life of bearing expected for 90% of probability of survival:
L07 L10 = ln ( 1/P07)ln (1/P10)1/b

Where,
P07=0.93, P10=0.90
b=1.34 ……………….. (For ball bearing P.S.G. /4.2)
L10=256.853 mr
Fixing bearing series based on excessive radial load factor:

Pe= [V × X × Fr × Kr ] S × Kt
Pe= equivalent load
V= Ring rotation factor,
If outer race is fixed, V=1
If outer race is moving, V=1.2
S=service factor =1.2… (Assuming medium shock load )

X=Radial load factor =1

Kr=Excessive radial load factor
If Fa/Fr < 0.3, then Kr =1.2
If 0.3 < Fa/Fr >0.5, then Kr =1.3
If Fa/Fr > 0.5, then Kr=1.5
Pe= [1×1×1.226×1.5]1×1.2
Pe = 2.206 KN

Dynamic capacity (C):

C = (L10)1/K× Pe
K= 3 ………………………… (For ball bearing P.S.G. /4.2)
C = (267.45)1/3×2.206
=15.5017 kN (1550 kg-f)

Selection of suitable bearing series:

Table 4.3: Bearing series
Series I.D. (mm) C0 (kgf) C (kgf) Max. RPM
6305 25 1040 1660 10000
6306 30 1460 2200 10000
6207 35 1370 2000 10000
6009 45 1270 1630 10000

Based on economical criteria and safety condition, selecting

Bearing Series 6305
Dynamic capacity (C) =1660 Kg-f
Static capacity (Co) =1040 Kg-f

Checking for the actual bearing life :

Equivalent load on bearing
Pe = [(V × X × Fr) + (Y×Fa)] S × Kt
To find X and Y:
For bearing at D, FaCo = 59610400 =0.057
∴ e = 0.27
FaV×Fr = 596 473.91 =1.2526 >
∴ X=0.56 , Y=1.6,

Pe = [(1 × 0.56 ×473.91) + (1.6×596)] 1.2 × 1

= 1462.78 N

Life of bearing for 90% probability of survival

L10= 166001462.783= 1461 mr > expected life

Hence, Bearing is Safe.

RESULT:
Selecting the bearing series 6305 on dynamic load carrying capacity of 1.660 kN
for 93% probability of survival and then checked it so that whether its L10 life is more
or less from the expected life.
Hence, it is a safe condition.
 4.3 Importance Of Chain Drive In Unidirectional
Gearbox [8]

Tooth
Type Roller Chain V Belt Spur Gear
Belt

Synchronization

Transmission Efficiency

Anti-Shock

Noise/Vibration

Avoid Heat,
Avoid Water, Avoid Heat, Oil,
Surrounding Condition Oil, Water, Avoid Water, Dust
Dust Water, Dust
Dust
Space Saving
(High Speed/ Low Load)

Space Saving
Less Durability Due
(Low Speed/ High Load) Compact Heavy Pulley Wider Pulley
to Less Engagement

Lubrication
Required No Lube No Lube Required

Layout Flexibility

Excess Load onto Bearing

Table 4.4: Comparison of different types of mechanical drives

Excellent Good Fair Poor

Generally, under the same transmission conditions, the cost of toothed belts
and pulleys is much higher than the cost of chains and sprockets.
 Features of Chain Drives:
1. Speed reduction/increase of up to seven to one can be easily accommodated.
2. Chain can accommodate long shaft-center distances (less than 4 m), and is more
versatile.
3. It is possible to use chain with multiple shafts or drives with both sides of the chain.
4. Standardization of chains under the American National Standards Institute (ANSI), the
International Standardization Organization (ISO), and the Japanese Industrial Standards
(JIS) allow ease of selection.
5. It is easy to cut and connect chains.
6. The sprocket diameter for a chain system may be smaller than a belt pulley, while
transmitting the same torque.
7. Sprockets are subject to less wear than gears because sprockets distribute the loading
over their many teeth.
4.4 Chain Design
Power to be transmitted, N = 0.97KW
Input speed n1 =210rpm
Velocity ratio, i =2
Service factor
KS =K1 × K2 × K3 × K4 ×K5× K6 ………………………. P.S.G.7.76
K1, load factor =1
K2, distance regulation factor =1
K3, center distance factor =1
K4, position of sprocket factor =1
K5, lubrication factor =1
K6, rating factor =1
KS = 1×1×1×1×1×1 =1

Number of teeth on driver & driven

Since i =2
Z1 = 16 , Z2 =32
Selection of pitch (P)
Since n=210 rpm …….(200 < rpm < 500 )
Hence selecting pitch P =12.7
Pitch circle diameter of sprocket (p.c.d)

d1 = Psin 180Z1 = 12.7sin 18016 = 65.09 mm

d2 = Psin 180Z2 = 12.7sin 18032 =129.56 mm.

Speed of chain (V1)

V1= πdN60,000 m/sec.
 = π×65.09×21060,000
= 0.715 m/sec.

Power transmitted on basis of Breaking Load (Q) ....…………….. P.S.G.7.77

N=Q ×V1102 ×n ×KS
Q=102 ×N ×n ×KSV1
Q=102 ×0.97 ×7.8 ×10.715
= 1079.34 kg-f

Chain selection Based on breaking load ………………………P.S.G.7.71

Table 4.5 : selection of chain

Roller
Transverse Bearing Breaking
Chain No. Pitch Dia. Wt/Length
Pitch area Load
Max.

p Dr Pt A w Q
Iso/din Rolon
mm. mm. mm. cm2 Kg-f Kg-f

08A-1 R40 12.7 7.95 11.7 0.44 0.69 1410

Check for bearing stress

σbr =Allowable bearing pressure
= 3.15 kg-f/mm2 ……………………………………………………P.S.G.7.75

Induced Bearing stress(σ)

σ =102 ×ks ×NA×V
σ =102 ×1 ×0.970.44 ×0.715 =314.49 kg-f/cm2
= 314.49×10-2 kg-f/mm2
= 3.1449 kg-f/mm2
Since σ < [σbr]
∴ Design is Safe.
 Lp =2a + ( Z2+Z1 2 ) + Z2-Z12π2ap
Where LP , length of continuous chain in multiple of pitches
aP ,approximate center distance in multiple of pitches
ap = a0p
where a0 ,assumed center distance (a0 = 90mm )
ap = 9012.7 = 7.086
Lp = (2×7.086) + 32+162 + 32-162π27.086

Lp = 14.17 + 24 + 0.162 = 39.087

Corrected to even no. ∴ Lp = 40
Exact center distance (a)
a = e + e 2- 8 m 4×pitch
e = LP - Z1 + Z2 2
= 40 - 32+16 2
e =16 (assume e=16)
m = Z2-Z12π2 = 32-162π2 = 6.48 ( m = constant)
a = 16 + 162 – 8 × 6.484 × pitch
= 7.57 ×12.7

a = 96.16 mm

L = LP × P (L = chain length)
= 40 × 12.7
= 508 mm
Actual factor of safety [n]………………………………………… P.S.G.7.78
[n]=Qp
Q=1410 kg-f
P = Pt+ Pc+ Ps
Where,
Pt = Tangential load
=102×N×KSV= 102×0.97×10.715 = 138.37 kg-f
Pc = Centrifugal load
=w ×v2g =0.69 ×0.71529.8 = 0.035 kg-f

Ps = load due to sagging

 = k × w × a =4 × 0.69 ×90 × 10-3 = 0.248 kg-f.
Where,
K= coefficient of sag,
w= weight per meter length,
a= center distance in meter.

P =P t +Pc +Ps
P =138.37+ 0.035+ 0.2484 = 138.66 kg-f
∴ [n] =QP = 141038.66 = 10.16
As [n] > 7.8 (min f. o. s ) ……….. Safe condition.

Effect of no. of sprocket teeth on the output shaft on various

parameters of Uni- Direction gear box

1. No. Of teeth on sprocket of input shaft = 16 ( Fixed)

2. No. Of teeth on sprocket of ideal shaft = 16 ( Fixed)
3. Speed of input sprocket = 180
rpm.
4. Tension in the chain = 1200 N.
Sr. No. No. of teeth on
P.C.D. Of O/P Shaft
O/P sprocket Torque Power
sprocket speed
(N-m) (W)
(m) (rpm)

1 16 0.0659 180 39.06 738.2

2 12 0.049 240 29.4 740.9
3 10 0.041 288 24.66 745.7
4 8 0.0371 360 22.26 841.4
Table 4.6 :- Effect of no. of teeth of sprocket on various parameter of Uni- Direction gear box
 Graph 4.2. Graph showing effect of decrease in no. of t teeth on the output shaft speed & power

Therefore, selecting sprocket with 8 teeth on the output shaft to increase the
output speed, torque & power.
 4.5 Side Plate Design

Fig.4.2 schematic of side plate

Material Selection:-
Cast Iron (MEEHANITE CASTING) GE50 (flake graphite / pearlitic)…....... PSG1.3
Yield strength (σyt)= 140 N/ mm2.
Assume F.O.S =7.
Tensile stress, σt= σytF.O.S.= 1407=20 N/mm2.
Shear Stress, τ=0.5× σytF.O.S.= 0.5×1407=10 N/mm2
A] Tearing Failure in plate section 1-1
σt = LoadArea
= Wmax. (195-47)×12= 1814.08316 (195-
47)×12 = 1.021 N/mm2
B] Shearing Failure in plate section 1-1
τ = LoadShear Area

= Wmax. 2×45×12= 1814.08316 2 ×45×12 = 1.68 N/mm2.

C] Tearing Failure in plate section 2-2
σt = LoadArea
= Wmax. (295-94)×12= 1814.08316 (295-94)×12 = 0.75 N/mm2.
∴ Hence, Design is Safe
 CHAPTER: 5
ANALYSIS
OF SHAFT

5.1 Analysis of Shaft

 Entity Size
Nodes 416
Element 1228
MESH:

ELEMENT TYPE:
Connectivity Statistics
TE4 1228 (100.00%)

ELEMENT QUALITY:
Table 5.1 : Elemental quality of shaft

Criterion Good Poor Bad Worst Average

1226 2 0 0.568
Stretch 0.278
(99.84% ) ( 0.16% ) ( 0.00% )
1196 32 0 2.218
Aspect Ratio 5.813
(97.39% ) ( 2.61% ) ( 0.00% )

MATERIAL:
Table 5.2 : Properties of Material selected shaft 1
Material Steel
Young’s Modulus 2×1011 N/m2
Poisson's ratio 0.266

Density 7860kg/m3

Coefficient of thermal expansion 1.17×10-5 /K deg

Yield strength 2.5×108 N/m2

STATIC CASE:

Fig.5.1 Model of input shaft 1

STRUCTURE COMPUTATION:

Number of nodes : 416

Number of elements : 1228
Number of D.O.F. : 0
Number of Contact relations : 0
Number of Kinematic relations : 0

LOAD COMPUTATION:
Applied load resultant:
Fx = 4. 610e-008 N
Fy = -1. 933e+003 N
Fz = -1. 700e+003 N
Mx = 3. 842e+001 N-m
My = -1. 450e-007 N-m
Mz = 1. 659e-007 N-m
 Table 5.3 : Forces & moment acting on the shaft

Relative
Components Applied Forces Reactions Residual
Magnitude Error
Fx (N) 4.61×10-8 -4.698×10-18 2.0188×10-12 6.5414×10-15
Fy (N) -1.9327×103 1.9327×103 1.5916 ×10-12 5.1572×10-15
Fz (N) -1.7004×103 1.7004×103 1.3870× 10-11 4.4941×10-14
Mx (N-m) 3.84×101 -3.8415×101 -5.187×10 -13 1.6427×10-14
My (N-m) -1.45×107 1.4500×10-7 -1.391 ×10-13 4.4074×10-15
Mz (N-m) 1.6594×107 -1.6594×10-7 8.928 × 10-14 2.8281×10-15

STATIC CASE SOLUTION - DEFORMED MESH:

Fig. 5.2 Deformation in a shaft

STATIC CASE SOLUTION - VON MISES STRESS (NODAL VALUES):

Fig. 5.3 Analysis of a solid shaft

5.2 Analysis of Side Plate 1

MESH:
Entity Size
Nodes 588
Elements 1437

ELEMENT TYPE:
Connectivity Statistics
TE4 1437 (100%)

ELEMENT QUALITY:
Table 5.4: Elemental quality of side plate 1
Criterion Good Poor Bad Worst Average
1437
Stretch 0 (0.00%) 0 (0.00%) 0.429 0.591
(100%)
Aspect 1437
0 (0.00%) 0 (0.00%) 2.647 2.161
ratio (100%)
 MATERIAL:
Table 5.5: Material properties of side plate 1
Material Iron
Young’s modulus 1.2× 1011 N/m2
Poisson’s ratio 0.291
Density 7870 kg/ m2
Coefficient of thermal conductivity 1.21 ×10-5 /kdeg
Yield strength 3.1×108 N/ m2

STATIC CASE:

Fig. 5.4 Model of a Plate

STRUCTURE COMPUTATION:
Number of nodes : 588
Number of elements : 1437
Number of D.O.F. : 1764
Number of contact relation :0
Number of kinematic relations :0
Linear tetrahedron : 1437

LOAD COMPUTATION:
Applied load resultant:
Fx= -4.459 × 10-8 N
Fy = -5.347 × 103 N
Fz = -4.906 × 103 N
Mx = 8.688 × 102 N-m
My = 2.943 × 101 N-m
Mz = -3.208 × 101 N-m
Table 5.6: Forces & moment acting on the Side plate 1
 Relative
Applied
Components Reactions Residual Magnitude
Forces
Error
Fx (N) 4.4587×10-9 -4.4605×10-8 -1.7792×10-11 2.0716×10-14
Fy (N) -5.3467×103 5.3467×103 -3.5470×10-11 4.1299×10-14
Fz (N) -4.9058×103 4.9058×103 -2.0009×10-11 2.3297×10-14
Mx (N-m) 8.6884×102 -8.6884×102 6.4801×10 -12 2.5150×10-14
My (N-m) 2.9435×101 -2.9435×101 -3.1797×10-12 1.2341×10-14
Mz (N-m) -3.2080×100 3.2080×101 4.6185× 10-13 1.7925×10-15

STATIC CASE SOLUTION - DEFORMED MESH

Fig. 5.5 Deformation in a plate

STATIC CASE SOLUTION - VON MISES STRESS (NODAL VALUES)

 Fig. 5.6 Analysis of a plate

5.3 Analysis of Second Side Plate 2

MESH:
Entity Size
Nodes 588
Elements 1437

ELEMENT TYPE
Connectivity Statistics
TE4 1437 (100%)

ELEMENT QUALITY
Table 5.7: Elemental quality of side plate 2
CRITERION Good Poor Bad Worst Average
1437
Stretch 0 (0.00%) 0 (0.00%) 0.429 0.591
(100%)
Aspect ratio 1437(100%) 0 (0.00%) 0 (0.00%) 2.647 2.161

MATERIAL
Table 5.8: Material properties of side plate 2
Material Iron
Young’s modulus 1.2× 1011 N/m2
Poission’s ratio 0.291
Density 7870 kg/ m2
Coefficient of thermal conductivity 1.21 ×10-5 /kdeg
Yield strength 3.1×108 N/ m2

STATIC CASE:

Fig. 5.7 Model of a Plate 2

STRUCTURE COMPUTATION
Number of nodes : 588
Numberof elements : 1437
Number of D.O.F. : 1764
Number of contact relation :0
Number of kinematic relations :0
Linear tetrahedron : 1437

LOAD COMPUTATION
Applied load resultant:
Fx= -1.048 × 10-9 N
Fy = -1.422 × 103 N
Fz = -1.788 × 103 N
Mx = 2.654 × 102 N-m
My = 1.073 × 101 N-m
Mz = -8.53 × 100 N-m

Table 5.9 : Forces & moment acting on the Side plate 2

Relative
Components Applied Forces Reactions Residual Magnitude
Error
Fx (N) -1.0477×10-9 1.0477×10-9 5.3788×10-12 1.7851×10-14
Fy (N) -1.4217×103 1.4217×103 -7.9581×10-12 2.6412×10-14
Fz (N) -1.7880×103 1.7880×103 -7.7307×10-12 2.5657×10-14
Mx (N-m) 2.6539×102 -2.6539×102 1.8190×10 -12 2.0123×10-14
My (N-m) 1.0728×101 -1.0728×101 -1.0676×10-12 1.1811×10-15
Mz (N-m) -8.5304×100 8.5304×100 9.700 × 10-14 1.0808×10-15

STATIC CASE SOLUTION - DEFORMED MESH

Fig. 5.8 Deformation of a Plate 2

STATIC CASE SOLUTION - VON MISES STRESS (NODAL VALUES)

 Fig. 5.9 Analysis of a Plate 2

6. COST ESTIMATION OF ENTIRE PROJECT

Volume Density
Sr. No. Component Material Mass Cost
m3 Kg/m3
0.00222967 876.26
1 Side Plate MS 7860 17.52
2 1
0.00077910
2 Shaft MS 7860 6.5 390
6

Bearing Cost
Quantity of bearing = 8 Nos.
Cost per bearing = Rs. 90/-
Total cost of bearing = Rs. 720/-

Cost of chain & sprocket

Cost of chain = Rs. 130/-
Cost of Sprocket= Rs. 330/-

Others (including nuts & bolts) = Rs. 200/-

Total cost of gear box unit = Rs. 2,646.26/-

 7. CONCLUSION

1. The power transmission system (i.e. Uni direction gear box ) fabricated in
laboratory by using chain & sprocket mechanism gives an output of 9.196 W.
This brings the efficiency of the system to 24.2 % .
Input power = 38 W.
Output power = 9.196 W.
∴ ηsytem= Out put powerIn put power
= 9.19638=0.242=24.2%

2. In the Uni- direction gearbox, reduction in the no. of teeth on output sprocket
increases the speed of output shaft and power available at output.
3. Reduction in shaft diameter contributes to the reduction in the net weight of the
system thereby increasing efficiency of system.

1. SCOPE OF THE PROJECT

1. The size of system can be reduced, by reducing various parameter like shaft
diameter, no. of teeth on sprocket, so that efficiency can be increased.
2. Analysis of chain sprocket mechanism can be done to check for any failure.
3. Uni -direction gear box also can be made by using other technique like worm
and worm wheel type.
BIBLIOGRAPHY

1. Energy from sea waves-the Indian wave energy programme- M.Ravindran and
Paul Mario Koola, CURRENT SCIENCE,VOL. 60,NO.12,25 JUNE 1991
2. Wave Energy Generation Device: Design, Development, and
Implementation-
S. G. Kanitkar, J.G. Kori, Suhas Deshmukh, S. N. Teli.
3. Ocean Wave Energy Conversion-Jennifer Vining
4. Ocean Wave Energy Overview and Research at Oregon State University- Ted
K.A. Brekken, Annette Von Jouanne, Hai Yue Han.
5. Ocean Energy Conversion in Europe,Centre for Renewable Energy
Sources,2006
6. P.S.G. design data
7. Machine design-v.b.bhandari

WEBSITES
1. http://chain-guide.com/basics/1-chain-basics.html
2. http://www.urbanhart.com/shopsite/rope_rollers.html
3. http://www.definition-of.com/OCEW">OCEW</a>
4. http://www.oceanpowertechnologies.com/projects.htm4.
5. http://www.oceanpowertechnologies .com
6. http:// www.enchantedlearning.com/subjects/ocean/Waves.shtml
7. http://www.wavesenergy.com/links.html
8. http://www.oceanpowermagazine.net/2010/03/01/india-studies-feasibility-of-
over- 100-megawatts-of-tidal-energy-projects.

SOFTWARES USED
1. CATIA V5R17
2. AUTOCAD 2010
3. MICROSOFT OFFICE 2010
APPENDIX
NOMENCLATURE
H Significant wave height
T Zero crossing period in sec.
E Energy stored in a horizontal square metre of the water surface.
P Wave energy flux
Cg Group Velocity of wave(m/s)
V Velocity of float (m/s)
Mt Torque on the shaft
Tt Tension on tight side of chain
Ts Tension on slack side of chain
Tc Resultant tension
θ Angle of wrap of the chain
Kb , Kt Combined fatigue and shock load factor.
Mbe Equivalent bending moment
Mte Equivalent twisting moment
d Shaft diameter
Fr radial Load
Fa Axial load
N Bearing speed
Lhr Expected life in hrs.
Kt Temperature Factor
Pe Equivalent load
V Ring rotation Factor
Kr Excessive radial load factor
C Dynamic capacity
Co Static capacity
Ks Service factor for chain design
Z1, Z2 No. of teeth on driver & driven sprocket
N Power transmitted
Q Breaking load
Lp Length of continuous chain
ap Approximate centre distance between the sprocket
a Exact centre distance

*********************************