d esign and fabrication of a vehicle with inbuilt pneumatic … · 2018-05-06 · d esign and...

DESIGN AND FABRICATION OF A VEHICLE WITH INBUILT PNEUMATIC JACK

C.JAGADEESH VIKRAM1, D.MOHAN KUMAR2,

Asst Professor1,2 ,Department of Automobile Engineering ,

BIST, BIHER, Bharath University,Chennai – 73.

[email protected].

ABSTRACT:

There are many safety hazards posed with manually

raising a vehicle to change a tire. Standard car

jacks pose a great safety hazard due to the physical

and time consuming involvement of the operator.

Aftermarket automatic hydraulic jacks though safer

still are hazardous as they have to be manually

placed under the vehicle and have limited use. A

pneumatic car jack that is permanently attached to

the under body of a vehicle will reduce and

eliminate many of these safety issues.

The pneumatic jack was designed based on the

relative weights of the customer requirements that

are given the most importance and the engineering

features with the highest relative importance in

order to ensure that customer needs are met. This

approach ensured that the car jack was designed

with the customer’s needs in sight and thus proved

to be a successful product.

INTRODUCTION

The standard vehicle jacks require the

operator to retrieve the jack from the trunk,

place it under the vehicle in the proper location,

and then manually rotate the screw thread in

order to lift the vehicle[1-5]. This process is time

consuming, physically demanding and poses

several safety hazards. Adverse weather

conditions can exacerbate the process and make

it a greater safety hazard. Those who are

physically weaker (women, senior citizens,

young drivers) may face great difficulties in

jacking a vehicle in case of an emergency

repair[6-9]. The purpose of this senior design

project is to counter the safety hazards and

physical demands related to using manual jacks

or aftermarket hydraulic jacks by designing a

jack system that is permanently attached to the

vehicle. This vehicle mounted jack system will

be automated so that operator input is kept to a

minimum and thus safety hazards can be

avoided[10-16].

DESCRIPTION OF COMPONENTS

Chassis

Chassis is a French term and was

initially used to denote the frame parts or Basic

Structure of the vehicle. It is the back bone of

the vehicle. A vehicle without body is called

Chassis. The components of the vehicle like

Power plant[17-21], Transmission System,

Axles, Wheels and Tyres, Suspension,

Controlling Systems like Braking, Steering etc.,

and also electrical system parts are mounted on

the Chassis frame. It is the main mounting for all

the components including the body. So it is also

called as Carrying Unit[22-29].

Motor

Most commonly used electrical drives

are: DC motors – shunt, series, compound and

permanent magnet.

Induction motors: squirrel cage, wound rotor

and linear.

Synchronous motors: wound field and

permanent magnet.

Classification of Electrical Drive

International Journal of Pure and Applied MathematicsVolume 119 No. 12 2018, 9901-9913ISSN: 1314-3395 (on-line version)url: http://www.ijpam.euSpecial Issue ijpam.eu

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DC drives: A dc motor speed can be controlled

by using a power converter. Here motor is

coupled with load[30-35].

AC drives: An AC motor speed can be

controlled by a power converter. Here motor is

coupled with load. The main purpose is to vary

the motor speed.

Principle of Operation

The basic principle of operation of d.c

motor is, “whenever a current Carrying

conductor placed in a magnetic field, the

conductor experiences a force tendingto move

it.” Refer the following Fig1.2 shows the types

of Motor.

Types of DC Motors

Fig: 1-Classification of motor

The classification of DC motors

is similar to that of the DC generators. The

classification is based on the connections of field

winding in relation to the armature[42-48]. The

types of DC motors are

1) Separately excited DC motor

2) Self-excited DC motor

o Series motor

o Shunt motor

o Compound motor

Pneumatic Systems

Pneumatics is a branch of mechanics

that deals with the mechanical properties of

gases. It works with the study of pressurized gas

that produces mechanical motion, and the

application of such gases to produce motion.

Systems based on pneumatics are found in

factories that deal with compressed air and inert

gases. Energy produced by pneumatic systems

can be more flexible, less costly, more reliable

and less dangerous than some actuators and

electric motors[36-41].

Fig: 2-.Pneumatic Systems

Pneumatic systems used extensively

in industry are commonly powered

by compressed air or compressed inert gases. A

centrally located and electrically

powered compressor powers cylinders, air

motors[49-53], and other pneumatic devices. A

pneumatic system controlled through manual or

automatic solenoid valves is selected when it

provides a lower cost, more flexible, or safer

alternative to electric motors and actuators. Most

industrial pneumatic applications use pressures

of about 80 to 100 pounds per square inch (550

to 690 kPa). Pneumatic systems generally have

International Journal of Pure and Applied Mathematics Special Issue

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long operating lives and require little

maintenance. Because gas is compressible,

equipment is less subject to shock damage. Gas

absorbs excessive force, whereas fluid in

hydraulics directly transfers force. Compressed

gas can be stored, so machines still run for a

while if electrical power is lost.

Components of Pneumatic System

Pneumatic technology deals with the

study of behavior and applications of

compressed air in our daily life in general and

manufacturing automation in particular.

Pneumatic systems use air as the medium which

is abundantly available and can be exhausted

into the atmosphere after completion of the

assigned task.

Basic Components of Pneumatic System

Important components of a pneumatic

system are given below

a) Air filters: These are used to filter out the

contaminants from the air.

b) Compressor: Compressed air is generated by

using air compressors. Air compressors are

either diesel or electrically operated. Based on

the requirement of compressed air, suitable

capacity compressors may be used.

c) Air cooler: During compression operation, air

temperature increases. Therefore coolers are

used to reduce the temperature of the

compressed air.

Fig:3 -.Basic Components of Pneumatic Systems

d) Dryer: The water vapor or moisture in the air

is separated from the air by using a dryer.

e) Control Valves: Control valves are used to

regulate, control and monitor for control of

direction flow, pressure etc.

f) Air Actuator: Air cylinders and motors are

used to obtain the required movements of

mechanical elements of pneumatic system.

Actuators

Actuators are output devices which

convert energy from pressurized hydraulic oil or

compressed air into the required type of action

or motion. In general, hydraulic or pneumatic

systems are used for gripping and/or moving

operations in industry. These operations are

carried out by using actuators.

Actuators can be classified into three types.

1. Linear actuators: These devices convert

hydraulic/pneumatic energy into linear

motion.


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2. Rotary actuators: These devices convert

hydraulic/pneumatic energy into rotary

motion.

3. Actuators to operate flow control valves:

these are used to control the flow and

pressure of fluids such as gases, steam

or liquid.

Double Acting Cylinder

The main parts of a hydraulic double

acting cylinder are: piston, piston rod, cylinder

tube, and end caps. The piston rod is connected

to piston head and the other end extends out of

the cylinder. The piston divides the cylinder into

two chambers namely the rod end side and

piston end side. The seals prevent the leakage of

oil between these two chambers. The cylindrical

tube is fitted with end caps. The pressurized oil,

air enters the cylinder chamber through the ports

provided. In the rod end cover plate, a wiper seal

is provided to prevent the leakage of oil and

entry of the contaminants into the cylinder. The

combination of wiper seal, bearing and sealing

ring is called as cartridge assembly. The end

caps may be attached to the tube by threaded

connection, welded connection or tie rod

connection. The piston seal prevents metal to

metal contact and wear of piston head and the

tube. These seals are replaceable. End

cushioning is also provided to prevent the

impact with end caps.

Fig: 4-.Double Acting Cylinder

Types of Direction Control Valve

Fig: 5-.Types of Direction Control Valve

Actuation System of Valve

There are different types of actuation

system, which will make the valve to change the

position for changing the operating the

pneumatic cyclinder.

Fig: 6-.Actuation System of Valve

Gear

In spur gears, the teeth are straight and parallel

to the axis of the wheel. The gearing so formed

is called spur gearing. They are used to transmit

rotary motion between parallel shafts. This

gearing may be internal or external. External

gears rotate in opposite directions while internal

gears rotate in same direction.


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Fig: 7-.Spur Gear

Rack

It is a type of linear actuator that

comprises a pair of gears which convert

rotational motion into linear motion. A circular

gear called "the pinion" engages teeth on a linear

"gear" bar called "the rack", rotational motion

applied to the pinion causes the rack to move

relative to the pinion, thereby translating the

rotational motion of the pinion into linear

motion.Here, we use the rack and pinion

arrangement to control the horizontal motion of

the welding.

Fig: 8-.Rack

Compressor

Compressed air energy storage (CAES)

is a way to store energy generated at one time

for use at another time using compressed air. At

utility scale, energy generated during periods of

low energy demand (off-peak) can be released to

meet higher demand (peak load) periods. Small

scale systems have long been used in such

applications as propulsion of mine locomotives.

Large scale applications must conserve the heat

energy associated with compressing air;

dissipating heat lowers the energy efficiency of

the storage system.

Fig: 9-.Compressor

Bearing

A bearing is a device to allow

constrained relative motion between two or

more parts, typically rotation or linear

movement. The bearings are used in variety of

machine elements to guide and allow the relative

motion between the parts with minimum

frictions and maximum accuracy.

Fig: 10 -.Bearings

WORKING CONCEPT

Fig: 11 -.Block Diagram for Pneumatic Jack


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Parts of Diagram

1. Pneumatic cylinder

2. Wheels

3. Frame

4. Bumper

Working

As when the motor is ON, then the gear gets

rotated over the rack and we can fix the gear

either at the front end or at the rear end. Then by

passing the compressed air we can able to lift the

chassis for servicing. That here the pneumatic

cylinder and the jack is fitted at the same plane.

Then they are perfect to use four wheelers.

Difference between Proposed and Existing

Model

EXISTING MODEL PROPOSED MODEL

They had using by

manual painting

system.

We are using rack

and pinion arrangement

mechanism.

Manual work will be

more.

We have been

reducing the manual

work.

METHODOLOGY

Drilling

Drilling is the process of

removing the materials with the help of drill for

making a hole of circular cross section in solid

materials. Drill bit is a multipoint cutting tool, it

is in motion along the perpendicular axis to the

work piece material and the workpiece is

stationary. Refer the following Fig3.6 shows the

Drilling Operation.

Welding

The process of joining the two

workpiece materials by using the electric arc is

known as arc welding. An electric current is

used to strike an arc between the base material

and the consumable electrode rod or stick. The

electrode rod is made of a material that is

compatible with the base material being welded

and covered with a flux that gives off the vapors

that serves as a shielding gas and provides a

layer of slag, both of which protect the weld area

from atmosphere.

Plain Turning

The process of removing the

material from workpiece to reduce the

dimension of it is known as plain turning.

Machining can be performed by using lathe, the

workpiece is placed in the chuck and tool is

placed at the tool holder. Then the workpiece

can be machined to the required dimension.

Refer the following Fig3.8 shows the Plain

Turning operation.

Grinding

A grinding machine, often shortened

to grinder, is any of various power

tools or machine tools used for grinding, which

is a type of machining using an abrasive

wheel as the cutting tool. Each grain of abrasive

on the wheel's surface cuts a small chip from the

work piece via shear deformation. Grinding is

used to finish work pieces that must show high

surface quality (e.g., low surface roughness) and

high accuracy of shape and dimension.

DESIGNCALCULATIONS

Calculation of Gear

Module m = 1.5

Outer diameter D = 70 mm

Module (m) = Outer diameter (D )

(Z+2)

1.5 = 70

Z+2

Z = 49


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Pitch circle diameter:

P.C.D = m x Z

= 1.5 x 49= 73.5 mm.

Circular pitch:

PC = 𝜋 x 𝑚

= π x 1.5

PC = 4.71

Teeth depth:

H = Z x m

2 [1 + 2

𝑍- cos (90

Z) ]

= 49 x 1.5

2 [1 + 2

49- cos (90

49) ]

= 36.75 [1 + 0.04 – 0.99]

H = 1.837 mm

Teeth thickness:

B = Z x m x sin ( 90

𝑍) =

49 x 1.5 x sin ( 90

49 )

= 49 x 1.5 x 0.03

B = 2.35 mm.

Addendum circle:

Da= m (1 + Z)

= 1.5 (1 + 49)

Da = 75 mm

Dedendum circle:

Db = D x cos α

= 70 x cos 20̊

Db = 65.77mm

Diametrical pitch:

Pd = 𝑍

𝐷

= 49

70

= 0.7 tooth/mm

Cone distance:

R = P .C .D

8

= 73.5

8

= 9.18 mm

Fillet radius:

r = 𝑃c

8

= 4.71

8 = 0.58

mm

4.1.2 CALCULATION OF BEARING

Diameter of bearing (D) = 60 mm

Load on bearing (w) = 5 N

Speed of bearing = 90 rpm

Length of bearing:

From PSG Data book Pg no: 7.31 for motor

L

D = 1.5

L = 1.5 x 60

L = 90 mm

Pressure developed:

P = w

L x D

= 5

90 x 60

= 0.9 x 10-3 N/mm

2

Selection of lubricating oil:

From PSG Data book Pg no: 7.31

(Z n

P)min = 2844.5


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= 2844 .5 𝑥 0.9 𝑥 10−3

90

Zmin = 2.92

From 7.41 for 4centipoise and 90º

Celsius SAE 10 oil will be selected.

Calculation of coefficient of Friction:

µ= 33.25

1010 x Z n

P x

D

C + K

Where C = 150 x 10-3 from PSG Data

book Pg no: 7.32

C = 150 x 10-3

D

C =

60

0.15

= 400

Therefore

µ = (33.25

1010 )(10000 x 90

0.9)x400+0.002

= 1.33

Heating Calculation:

Hg = µ w v

v = 𝜋 𝐷 𝑛

60 =

π x 0.09 x 90

60 v

= 0.42 m/s

Hg = 1.33 x 5 x 0.42

Hg = 2.82 w

Diameter of bearing:

Db = D + C

= 60 + 0.15

= 60.15 mm

4.2 DESIGN

The 3d modeling is done for its components and

assembled on CATIA and enclosed below

ASSSEMBLY MODEL

Fig: 12-. Pneumatic Jack-Assembly Model

CONCLUSION

Thus, by given above construction and

working, the research work is done successfully.

The design is done on Catia software. The

working model will be finished fully. Hence this

research work beats hydraulic jack and improves

its efficiency. This reduces human effort.

The air is required for pneumatics and it

is available enormous level in atmosphere. To

control the system, only ON and OFF are used

and the system consists only of standard

cylinders and other components, making it

simpler than hydraulics. As our jack is inbuilt

the work fatigue is less as well as cost is also

less.

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d esign and fabrication of a vehicle with inbuilt pneumatic … · 2018-05-06 · d esign and...

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