Air Word 8-1.docx

A PROJECT REPORT ON

DESIGN AND FABRICATION OF AIR FILLING MECHANISAM IN FOUR WHEELERS Submitted by

Payank Bharatbhai Patel Mehul Balubhai Katariya Sudhirkumar Ganpatbhai Patel Rushabh Hashmukhbhai Panchal

140160102078 140160102047 140160102081 140160102062

Guide by: Parth R Panchal In fulfillment for the award of the degree Of

BACHELOR OF ENGINEERING In AUTOMOBILE ENGINEERING

Government Engineering College, Modasa

Gujarat Technological University, Ahmedabad March, 2018

2018

Design & Fabrication Of Air Filling System Government Engineering College, Modasa

CERTIFICATE

This is to certify that the project reports, submitted along with the project entitled Design and fabrication of air filling mechanism in four wheeler has been carried out by Payank Patel, Mehul Katariya, Sudhir Patel and Rushabh Panchal under my guidance in partial fulfillment for the degree of Bachelor of Engineering in Automobile Engineering 8th Semester of Gujarat Technological University, Ahmedabad during the academic year 2018-19. These students have successfully completed project activity under my guidance.

Mr. Parth R. Panchal

Mr. U.V.Shah

Mr. Kunal V. Fadadu

Guide Automobile Department, GEC - Modasa, Gujarat

Head of Department Automobile Department, GEC - Modasa, Gujarat

Project Coordinator Automobile Department, GEC - Modasa, Gujarat

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INDEX CH.NO * * 1

2

3 4

5

6

DESCRIPTION Acknowledgement Abstract Introduction 1.1 Project Means 1.2 Aims Of Project 1.3 Process Planning 1.4 Project Planning 1.5 Definition of Market 1.6 Types of Market 1.7 Definition of Market 1.8 Importance at market research 1.9 Problem Statement 1.10 Basic Introduction 1.11 Advantage 1.12 Working Description Literature Review 2.1 Literature reviews 2.2 Methodology Objective Component Detail 4.1 Reciprocating Compressor 4.2 Solenoid Valve 4.3 Pressure Switch 4.4 Pressure Gauge 4.5 Connector 4.6 Hoses 4.7 Bearing 4.8 Wheels 4.9 Rotary Element Detail Design & Cad drawings 5.1 CAD drawing 5.2 CAD design of component 5.3 Different View of CAD assembly 5.4 Actual Prototype 5.5 Manufacturing Process 5.6 SWOT analysis 5.7 Flow process chart 5.8 Advantages 5.9 Application Costing 6.1 Cost structure

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PG.NO 5 6 6 6 7 8 8 9 9 9 10 10 10 11 12 14 14 16 17 17 19 20 21 23 24 25 27 28 28 30 30 31 32 33 34 35 36 38 40 40 41

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8 9 10 11 12

Canvas activity 7.1 AEIOU summary 7.2 Empathy canvas 7.3 Empathy mapping canvas 7.4 Product development canvas 7.5 Ideation canvas BMC canvas sheet BMC canvas report Periodic progress report Patent drafting exercise (PDE) Conclusion 12.1 Future scope 12.2 References

2018

42 43 45 46 47 50 52 56 57 73 79 79 80

FIGURE INDEX FIGURE.NO 1.1 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 5.1 5.3 5.4 5.5 5.6 5.7

FIGURE NAME Block diagram of system Reciprocating compressor Solenoid Valve Pressure Switch Pressure Gauge Push back connector T- joint PU pipe Bearing Wheel Rotary element Base Front view of assembly side view of assembly back view of assembly top view of assembly SWOT analysis

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ACKNOWLEDGMENT It gives us immense pleasure in submitting this project entitled “Design & Fabrication on Air Filling Mechanism in Four Wheeler “as a partial fulfilment for the B.E. Automobile Engineer Course at Government Engineering College, Modasa. Foremost, I would like to express my sincere gratitude to my guide Prof. Parth R. Panchal for the continuous support of my Project study and research, for his patience, motivation, enthusiasm, and immense knowledge. His guidance helped me in all the time of research and writing of this report. I could not have imagined having a better advisor and mentor for my Project study. Besides my advisor, I would like to thank to P r o f . K u n a l V . F a d a d u , Project Coordinator, Automobile Engineering department, who gives guidance for the Project work and their insistence for meeting deadlines we can do such excellent work. I offer my special gratitude to all the faculty members, Automobile Engineering Department, Government Engineering College, Modasa for their help and support. I thank to my friends for providing me such a warm atmosphere to make my study more delightful and memorable. I would like to express endless gratitude to “My Parents” who gave me everything they could to enable me to reach the highest possible education level. I only hope that they know how their love, support and patience encouraged me to fulfill their dream. I would like to thank all people who have helped and inspired me during my Report study.

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ABSTRACT The main aim of our project is to develop an “Automatic tyre inflation and deflation system” .This can be placed in all automobiles while long drives and that can be utilized while climbing uphill or down hills. It is very necessary for the every automobile to be cautious while driving through long distances. So we have fabricated this machine to fill the air automatically by using control units. In this project main function is suddenly the air is decreased to the automobile vehicles the sensor signal alerted to the person when the use of air tank to fill the air in the tyre. Then the air pressure is increased to the tyre in the vehicle it is same as the process of indicating the sensor signal through the person when the use of solenoid valve to reduce the excess air in the tyre. From the studies it is known that a slight drop in pressure, will affect the tyre wear, safety, gas mileage and whole vehicle performance. To neglect the unwanted stress and waste of time for inflating the tyres, this system is designed. This system states that the tyres are optimally inflated at all running conditions. With the consideration of environmental issues, this system reflects a potential improvement in fuel efficiency, tyre wear reduction and also overall performance of handling a vehicle in diverse conditions.

1.1 Project Means: Before taking the project work for foundation, it is quite necessary to have an exact idea of word “Project”. The word project consists of seven letters where its own significations have. P=Planning: Planning is the word which gives idea of processes to be done as a fact, a word without planning is just like a ship without the radar or a compass. R=Resources: Resources are the means, which guide to promote the function of the plant. Without suitable resources a project cannot work satisfactorily. There must be all necessary resources in project to good project work. O=Operation: Government Engineering College, Modasa

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Operation actually means all the type of work, which are promoted by the worker to complete the object. J=Joint Effort: It means those combined efforts of workers and other staff to complete the work. E=Engineering Function: Both the bodies like planning and engineering bodies work together with engineers through their techniques for good productions. All technical work is based on engineering function so it is very important. C=Communication: For execution of plan, the communication is very necessary. The material required for project work can only be through when proper communication is available. T=Task: Task of working body and control working body, as a matter of fact the word “Project” is used specially for construction purpose

1.2 Aims of Project  To prepare our self and to work individually.  To get the knowledge of each team member in various subject which we have studied up till now.  To develop an attitude of inquiry.  To develop skill in various functions of manufacturing.  To develop problem solving skill.  To develop skill of process planning & decision – making.  To develop ability of report writing.  To develop interdisciplinary exposure.  To develop the skill of analysing & evaluating of available data.  Apply knowledge about practical situation.  Participate effectively-group work/ team work.  To adopt the change of environment.  To understand

& accept information and information of running technology

 Quality control standard may be strong. Government Engineering College, Modasa

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 To increase the self-studies.  To calculate the cost, cost estimation, & costing.  To select the good ideas & good thinking.  To provide & develop the decision making.  To improve unity & discipline.

1.3. Process Planning Process planning is the fundamental of the industrial activities an efficient economy planning leads the firm to success. By process planning we can know the problems, which causes actual production. We know that for the Mfg. of a part many methods and process we should chose and easy

process. Time consumed during this process should be less and material

wastage should be less.

Advantages of Process Planning  It determines the most economical process from all possible process.  It determines sequence of operation to be performed.  It determines raw materials raw materials requirements it’s gross weight.  It helps in estimating and costing.  Process planning helps to prepare delivery schedule.

1.4 Project Planning After the selection of the project, planning is to be done. The success of the project depends on the keen, careful and efficient of the activities involved. In project planning we carried out, 1. MARKET SURVEYS 2. PROJECT CAPACITIES 3. SELECTION CAPACITIES 4. DESIGN CAPACITIES 5. RAW MATERIAL REQUIRMENTS 6. OPERATION PLANNING 7. METHOD AND TIME STUDY 8. MATERIAL HANDLING Government Engineering College, Modasa

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9. BUDGETING AND COSTING  The concept of project should be clear for each student. The project is the practical application of skill, abilities and knowledge.

1.5 Definition of Market Market is an organization where buyers and sellers are kept in close touch with each other and the products can be exchanged by money or anything “else” a perfect market is very wide deals in standardized commodity with buyer & seller equally well informed and bargaining for win-win situation.

1.6 Types of Market:SOME OF THESE ARE: 1.Factors markets in which entrepreneurs require some of the factors of production, land, labour etc. 2.Market for consumer goods-who sale and retail market. 3.Money market-market for securities. 4.Capital market-market for short-term loons. 5.Foreign exchange market-market for foreign currencies.

1.7. Definition of Market Demand:Market demand for a product class is the total volume which would be brought by a define customer group in a location in a demand time period under defined environmental condition and marketing effort. Market research today, has to be a very important part of the marketing function. Market research when properly connected and used on a regular basis is just as valuable to the manufacture as it is technical research and ensure the continued vitally of business. Market may be defined as the progress which information about the product from the market and analysis it systematically.

Market research includes following steps Government Engineering College, Modasa

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Classification of problems Research for loaning Field work Market potential Information Analysis Report Preparation. In first steps one must clear his aim about market researching second. It is decided that how information, data’s, opinions will be collected. At third step actual market research work at field market is being done. After that at fourth at and final stage according to analysis a results be propagated which can be easily understanding by anyone?

1.8. Importance at Market Research: It provides information about products development and product planning. It indicates the empty portion of market at where consumer is unsatisfied. It gives vital details to make sales forecasting. It magnifies the market volume. It finally represents the actual demand of consumer etc. We collect the information such as data, opinion etc. We also collect prize from a number from various stations. Meanwhile we also examine that is there any product with high value substituting the product.

1.9 Problem Statement: To develop an automatic air filling system, this recognizes and fills air in respective tyre when its pressure goes below the desired/required pressure (under inflated condition). Underinflated tires overheat more quickly than properly inflated tires, which cause damage to tires. To reduce this problem we are designing this system. As soon as a tyre Pressure goes under inflated, then a pressure sensor senses it and send it to the Controller which activates the solenoid valve and air is filled up to proper inflation.

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1.10 Basic Introduction: The “Automatic tyre inflation and deflation system” is a Mechanical device which is widely used in automobile works. The manual work increases the effort of the man power (operator) during the air checking in vehicles. The Air Maintenance Technology system developed through this project replenishes lost air and maintains optimal tire cavity pressure whenever the tire is rolling in service, thus improving overall fuel economy by reducing the tire’s rolling resistance. Automation can be achieved through computers, hydraulics, pneumatics, robotics, etc., of these sources, pneumatics form an attractive medium for low cost automation.

Today automobile sector plays a big role in the economics of all the countries in the world and lots of researches have been carried out to improve the efficiency of the vehicle one the techniques to improve the efficiency of an automobile is inflate the tyre regularly. As its well-known, one of the most serious problem that the large motor vehicle have whether they are for the transportation of passenger or cargo and especially those used for middle or longer distance travel, resides the ensuring the correct performance of the tires. This means making sure that tyre are inflated and stay inflated for the right amount of pressure for the load being carried and for road condition this way one can ensure not only the preservation of outer covering of the tires, but also the correct operation of vehicle without any risks.

The deflation is a process of letting air or gas out of the tires. Deflation is the problem of an automobile vehicle. Because a certain period of time in air reduced to the vehicle for running time. So a long distance travelled vehicle scar able things for deflation. The air is also decreasing the tyre. Fleet tyre managers typically ask how frequently they should be checking tyre pressure and loss so much of air during the course of the year. Osmosis of air through the tyre casing can lead to a loss 1to 3 PSI per month, depending on the specific tyre make and model. The type of compounds used in the manufacture of the tyre can have a big impact on osmosis. The composition and gauge of the tyre inner liner compound also plays significance in osmosis.

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1.11 Advantages:  The dynamically-self-inflating tyre system would be capable of succeeding as a new product in the automotive supplier industry. It specifically addresses the needs of the consumers by maintaining appropriate tyre pressure conditions for:  Reduced tyre wear  Increased fuel economy up to 15%.  Increased overall vehicle safety  Because such a product does not currently exist for the majority of passenger vehicles, the market conditions would be favourable for the introduction of a selfinflating tyre system.  Through extensive engineering analysis, it has also been determined that the selfinflating tyre system would actually function as desired. In particular, the product would be capable of:  Providing sufficient airflow to the tyre with minimal leakage withstanding the static and dynamic loading exerted on the rotary joints.  1.12 Working Description: If any prickle occurs in the tire of our vehicle, we get a gradual decrease in the tire pressure which obstructs our drive which may lead to an accident. Also at times, if we are stuck in some situation where we cannot get an immediate aid for the problem, this system is very useful and helpful for the purpose. In this system with decrease in pressure, sensor senses the pressure change and actuates the non-return valve which allows the compressed air from the compressor to pass to the tire from the LPC to make the pressure equal to the required pressure. Once the pressure gets equalized, the sensor cuts off the supply of compressed air by closing the non-return valve.

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Figure 1.1 – Block Diagram Of system In this system, compressor is connected to wheel with the help of hoses through a rotary joint. Pressure sensor and control circuit are connected between wheel and compressor. Two limits (upper limit and lower limit i.e. 20psi and 30 psi respectively) are set in the control circuit for automatic start and stop of compressor. Compressor works on 12V DC supply that is either a car battery or bike or an adapter. A non-return valve is connected between pressure sensor and compressor, so that the air flow must be unidirectional from compressor to tyre. When the pressure reduces below the lower limit (20psi) in the tyre during its rotation, pressure sensor senses this drop and starts the compressor automatically for the Government Engineering College, Modasa

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filling air into tyre with the help of control circuit. As soon as the pressure crosses the set upper limit (30psi), compressor stops working with the help of pressure sensor and control circuit. In this way, a proper required tyre pressure is maintained.

CHAPTER-2

LITERATURE REVIEW

2.1 Literature review A tyre is a ring-shaped covering that fits around a wheel's rim to protect it and enable better vehicle performance. Most tires, such as those for automobiles and bicycles, provide traction between the vehicle and the road while providing a flexible cushion that absorbs shock. The earliest tires were bands of iron placed on wooden wheels, used on carts and wagons. The tire would be heated in a forge fire, placed over the wheel and quenched, causing the metal to contract and fit tightly on the wheel. A skilled worker, known as a wheel Wright, carried out this work. The outer ring served to "tie" the wheel segments together for use, providing also a wear-resistant surface to the perimeter of the wheel. The word "tire" thus emerged as a variant spelling to refer to the metal bands used to tie wheels. The first practical pneumatic tire was made by Scottish inventor John Boyd Dunlop while working as a veterinarian in May Street, Belfast in 1887 for his son's bicycle, in an effort to prevent the headaches his son had while riding on rough roads S. Dunlop is credited with "realizing rubber could withstand the wear and tear of being a tire while retaining its resilience". The most important factors in tyre care are:      



Proper Inflation

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Pressure Proper

 Vehicle Loading 

Proper Tyre Wear

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Regular Inspection

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Good Driving Habits

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Vehicle Condition

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Bradley (1997) conducted a study of the effects of implementing CTI technology on tyre life. His study showed that with the implementation of CTI, a 90 % increase in the life of new drive tires is possible and a 26 % increase in life of retreaded tires. The number of tyres were damaged after the implementation of the CTI system was reduced by 28 %. Ljubics’s (1985) studies indicate that there is an optimum tyre pressure for a particular road surface in order to maximize fuel efficiency. However, unlike an asphalt road where fuel consumption steadily declines with an increase in tyre pressure, fuel consumption on a gravel road declines to a point and thereafter increases to almost mirror the decline.

Design of Automatic Tyre Inflation System: The aim of this study is to design and fabricate a system which works on automatic filling of air into a tyre that is in running condition with a low cost device. It automatically checks the pressure inside the tyre with the help of pressure gauge and ON the compressor which takes air from atmosphere, compresses it and then delivers the compressed air to tyre and ensures that tyres are always properly inflated to improve tyre life, human safety, reduction of gas mileage and vehicle performance. As the wheel is in rotating condition while filling of air into it, rotary joint is fixed between wheel spindle and wheel hub at each wheel so that there is no tangling of hoses.

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2.2 Methodology:

ASSEMBLY DRAWING

PART DRAWING

PURCHASE OF MATTERIAL

SELECTION OF MANUFACTURING PROCESS

SELECTION OF MATERIAL AND PREPARATION

START MANUFACTURING

SELECTION OF TOPIC ASSEMBLY OF MANUFACTURING PARTS LITRATURE REVIEW WORKING MODEL COLLECTING RESEARCH PAPER FINAL REPORT AREA OF SELECTION

NEED Government Engineering College, Modasa

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CHAPTER-3

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OBJECTIVE

3.1 Objective The overall goal of our design project is to develop a product that will decrease tire wear while improving fuel economy, performance and safety of a passenger vehicle through dynamically-adjustable tire pressures. However, there are several key objectives that the team has targeted our design to meet, and these objectives include both design characteristics and business objectives. Ability to Provide Proper Tire Pressure: The ideal functional objective of our design is its capability to adjust the pressures in all four tires of a passenger vehicle to obtain the proper pressure for varying road/driving conditions Ability to Provide Automatic System: A third objective is to provide all of the said benefits to the user through an automatic system, thus minimizing user intervention. Specifically, it is desired that the system automatically increase or decrease the tire pressures for the given road conditions. However, since this objective is closely linked with the ideal objectives in maintaining the proper tire pressure, and thus unattainable due to time constraints, this objective will not be pursued. Low Cost Device: For both the customer and end user (vehicle owner), it is imperative to keep the price of the device as low as possible. Considering the potential benefits and cost savings that this design has to offer and the prices of optional equipment for passenger vehicles with similar complexity, the target price range for this device has been identified as 5000-6000 INR. This is the price for both the OEM and vehicle owner, assuming that the OEM does not mark up the price. In addition, this price range should be able to support the costs of components of the system, manufacturing, and any necessary installation.

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1) Maintains the required tyre pressure: The function of the system is to maintain and adjust the pressure in all the tyres of the system according to varying loading and driving conditions. 2) An Automatic System: An automatic system further saves human energy & time in filling the air in tyres when they are in under inflated conditions. 3) Builds a Low cost system: The installation of such a system in vehicles is a low cost affair. 4) Improves fuel efficiency & tyre life: This system helps in less consumption of fuel and also improves tyre life by reducing chances of wear in tyre.

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CHAPTER-4

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COMPONENTES REQUIRED

Components necessary to fabricate automatic air inflation system are as follow: 1) Reciprocating Compressor 2) Solenoid Valve 3) Pressure Switch 4) Pressure Gauge 5) Connector 6) Hoses 7) Bearing 8) Wheel & tyres 9) Rotary element 10)

4.1 Reciprocating Compressor: Pneumatic systems operate on a supply of compressed air, which must be made available in sufficient quantity and at a pressure to suit the capacity of the system. The key part of any pneumatic system for supply of compressed air is by means using reciprocating compressor. A compressor is a machine that takes in air, gas at a certain pressure and delivers it at a higher pressure. Compressor capacity is the actual quantity of air compressed and delivered. And the volume expressed is that of the air at intake conditions namely at atmosphere pressure and normal ambient temperature. Clean condition of the suction air is one of the factors, which decides the life of a compressor. Warm and moist suction air will result in increased precipitation of condense from the compressed air. Built for either stationary (or) portable service the reciprocating compressor is by far the most common type. Reciprocating compressors deliver more than 500

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m³/min. In single stage compressor, even if the air pressure is of 6 bar, the machines can discharge pressure of 15 bars. Discharge pressure in the range of 250 bars can be obtained with high pressure reciprocating compressors that of three & four stages. Single stage and 1200 stage models are particularly suitable for pneumatic applications , with preferences going to the two stage design as soon as the discharge pressure exceeds 6 bar, because it in capable of matching the performance of single stage machine at lower costs per driving powers in the range.

Fig: 4.1 Compressors Applications: 

To supply high-pressure clean air to fill gas cylinders

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To supply moderate-pressure clean air to a submerged surface supplied diver



To supply moderate-pressure clean air for driving some office and school building pneumatic HVAC control system valves

 To supply a large amount of moderate-pressure air to power pneumatic tools, such as jackhammers For  filling tires

4.2 Solenoid Valve: A solenoid valve is an electromechanical controlled valve. The valve features a solenoid, which is an electric coil with a movable ferromagnetic core in its centre. This core is called the plunger. In rest position, the plunger closes off a

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small orifice. An electric current through the coil creates a magnetic field. The magnetic field exerts a force on the plunger. As a result, the plunger is pulled toward the centre of the coil so that the orifice opens. This is the basic principle that is used to open and close solenoid valves. Solenoids valves are used to close, dose, distribute or mix the flow of gas or liquid in a pipe. The specific purpose of a solenoid valve is expressed by its circuit function. A 3/2 way valve has three ports and two positions and can therefore switch between two circuits. 3/2 way valves can have different functions such as normally closed, normally open, diverting or universal.

Fig: 4.2 Solenoid valve Direct operated 3/2 way Solenoid Valve: A 3/2 way solenoid valve has three ports and two switching states. In each switching state, two of the three ports are connected. By activating the solenoid, the valve switches state and a different connection between the valve ports is established. The drawing below shows a direct operated 3/2 way valve. In the deenergized state, the medium can flow between from the port on the right side to the top port. In the energized state, the medium can flow from the left port to the right port. This is a called a normally closed 3/2-way valve.

4.3 Pressure Switch: The air compressor pressure switch helps to measure the pressure inside your air tank and then is used to shut off your compressor when your air tank reaches the desired air pressure.

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The air compressor pressure switch will also help your machinery maintain the proper pressure level as you go about your work. The switch can turn on your compressor when tank air pressure levels drop and more air is needed. This makes your air compressor pressure switch a part that gets used often, and so it may wear down sooner than others. You’ll want to keep it properly maintained and fix it, or replace it when any problems arise. The switch is your best protection against an over-pressurized tank and air lines for your compressor, keeping you safe from ruptures and dangers.

Figure 4.3 Pressure switch Working of pressure switch: Air compressor pressure switches use air lines to monitor pressurized air as it moves to and from your air tank. All pressure switches have some element that reacts when pressure is applied to it. The most common device is a diaphragm that will physically compress when exposed to this air.

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Air pressure in your compressor tank will increase and eventually build up enough backwards pressure also called cut-out pressure to change the shape of this diaphragm. Deformation here will cause movement in the pressure switch. When your air compressor pressure switch’s diaphragm is deformed enough, its movement will break contact inside the switch so that power stops flowing to the compressor’s motor circuit, stopping the compressor from further pressurizing the air in your tank. Constant air pressure at a specific volume will keep the diaphragm deformed. When the air pressure in your tank drops far enough, the diaphragm will revert back to its normal shape. Once this pressure called cut-in pressure lightens to a certain level, an internal operator within the diaphragm will deform in an opposite manner. This movement closes the circuit and starts the motor back up again. Your air compressor pressure switch continues this dance as long as your machinery is using compressed air. The cycle is broken when the unit is no longer powered externally or when there is an issue. Leaks at any point in your compressor’s pressure switch and nearby casing can stop your work and cause major problems.

4.4 Pressure gauge: Many techniques have been developed for the measurement of pressure and vacuum. Instruments used to measure and display pressure in an integral unit are called pressure gauges or vacuum gauge. A manometer is a good example as it uses a column of liquid to both measure and indicate pressure. Likewise the widely used Bourdon gauge is a mechanical device which both measures and indicates, and is probably the best known type of gauge.

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Fig: 4.4 Pressure gauge

4.5 Connectors: In our system hose connectors are used. Hose connectors normally comprise an adoptee hose nipple. These types of connectors are made up of brass (or) Aluminium (or) hardened pneumatic steel. For these type hose connectors no need of hose clamp these are self-locking hose connectors. The universal combination at an attractive price. Can be widely used thanks to resistant materials. Easy to install thanks to optimized bending radii. Limited reset effect. Attractively priced the universal solution for metal fittings. Perfect for standard pneumatic applications in many different fields. Wide range of variants Over 1000 types for maximum flexibility in standard applications. Hydrolysis resistant for applications in damp environments or in contact with water at up to 60 °C. Resistant to pressure secure connection when used with pressure ranges of up to 14 bar. Economical for pneumatic installations in the high pressure ranges.

Fig: 4.5 Push back connector The powerful combination for applications involving pressure ranges up to 16 bar For example, for applications with the pressure booster Robust, flexible and reliable connection for the automotive industry. Fulfils the requirements Heat resistant for reliable compressed air supply in high temperature ranges. Whether with 10 bar at 80 °C or 6 bar at 150 °C – always delivers maximum process security. Anti-static Electrically conductive tubing combined with a solid-metal fitting

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Approved for the food Industry Food and Drug Administration certification for use in the food industry:

Fig: T-joint The hydrolysis-resistant combination with increased functions. Designed to meet the highest demands, this combination shines in applications which require the highest possible hygiene standards for food. The cost-effective alternative to stainless steel, perfect for e.g. critical environments such as the splash zone: resistant to practically all common cleaning agents, with maximum corrosion protection. Resistant to media completely resistant to all cleaning agents and lubricants and even permits the transportation of acids without any problems. Flame-retardant Safe in areas where there is a risk of fire thanks to flameretardant properties to Resistant to welding Spatter The economical combination for applications not in close proximity to welding applications. Also reliable for applications in direct proximity to welding splatter Double-sheathed tube and special fitting.

4.6 Hoses: Hoses used in this pneumatic system are made up of polyurethane. These hose can with stand at a maximum pressure level of 10 N/m². Polyurethane combines the best properties of both plastic and rubber. It offers abrasion and tear resistance, high tensile and elongation values, and low compression set. Polyurethane is naturally flexible and exhibits virtually unlimited flexural abilities. Combining good chemical resistance with excellent weathering Government Engineering College, Modasa

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characteristics sets polyurethane apart from most other thermoplastics. It has exceptional resistance to most gasoline, oils, kerosene, and other petroleum based chemicals, making it an ideal choice for fuel lines (although additives in today’s gasoline and petroleum products warrant field testing).

Fig: 4.6 PU Pipe Applications of PU tube: 1) Any time condensation can occur with small actuators, air grippers and air operated valves. Condensation in a pneumatic system will cause operating failure and affect the life of pneumatic equipment. Manufacturers of electrical components. 2) When you need to eliminate water condensation but you cannot use a membrane or desiccant dryer (as you cannot use a fast exhaust).

Benefits of PU tube: 1).Longer life of other pneumatic equipment.



2).Prevents operational failure of small actuators, air grippers and pilot operated valves due to condensation.



3).Avoids corrosion in other pneumatic equipment. 4).Diffuses water vapour in the piping to the outside before it liquefies, so we avoid problems such as dried grease or ozone when using other types of dryers.



5).Easy mounting.

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4.7 Bearing: A bearing is a machine element that constrains relative motion to only the desired motion, and reduces friction between moving parts. The design of the bearing may, for example, provide for free linear movement of the moving part or for free rotation around a fixed axis; or, it may prevent a motion by controlling the vectors of normal forces that bear on the moving parts. Most bearings facilitate the desired motion by minimizing friction. Bearings are classified broadly according to the type of operation, the motions allowed, or to the directions of the loads (forces) applied to the parts.

Fig: 4.7 Bearing & holder

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4.8 Wheel: In this system 2 scooter wheels are used for rear drive & one castor wheel are used for front. DC motor with chain drive is connected to the rear 2 wheels.

Figure 4.8 wheel

4.9 Rotary element:Rotary joint or a Rotary Union is a device that provides a seal between a stationary passage and a rotating part. Stationary passage may be a pipe or tubing; whereas rotating part can be a drum, spindle or a cylinder. Thus it permits the flow of the fluid into and/or out of the rotating part. Generally the fluids that are used with the rotary joints and rotating unions are steam, water, thermal oil, hydraulic fluids etc. A rotary union will lock onto an input valve while rotating to meet an outlet. During this time the liquid and/or gas will flow into the rotary union from Government Engineering College, Modasa

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its source and will be held within the device during its movement. This liquid and/or gas will leave the union when the valve openings meet during rotation and more liquid and/or gas will flow into the union again for the next rotation.

Figure 4.9 rotary element

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CHAPTER-5 DETAIL DESIGN & CAD DRAWING 5.1 CAD Drawing: The assembly of tyre inflation system has been made in solidworks modelling software. Solidwork is a family or suite of design software supporting product design for discrete manufacturers and is developed by dassult system. Solidwork is 3-dimensional CAD/CAM/CAE feature-based, associative solid modelling software. It is one of a suite of 10 collaborative applications that provide solid modelling, assembly modelling, 2-D orthographic views, finite element analysis, direct and parametric modelling, sub-divisional and nub’s surfacing, and NC and tooling functionality for mechanical designers. The features used in solidwork for modelling of tyre inflation system are: Sketch: A sketch is a 2-D entity that graphically captures an idea with lines, constraints and dimensions. The tools used in sketch are line, arc, and circle Sweep: Sweeping is a modelling feature in which a closed planar shape is translated or revolved it form a solid. A sweep with a variable section is one of the most powerful feature in solidwork. A sweep utilizes a single section, which can be constant or variable, and that is swept along one or more trajectories. A sweep uses one or more trajectories and a single section that can change shape and orientation along the features. The main components of sweep tool are section and trajectories. Mirror: Mirror is a feature which is used to perform mirror or copy of a part with respect to center plane (top or bottom plane, front or back plane, right or left plane), Mirror eliminates modelling of same part in a given model, and it reduces time and makes work easy. It is very much useful in modelling complex part. Datum planes: Datum planes are 2-D reference geometry that is used to build feature geometry. It is used to create default datum planes. Datum planes are individual features that can be redefined, suppressed, hidden, or deleted. It is a planar reference that has no mass. It is infinite in size, but its display size can be edited.

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Extrude: Extrude a 2D sketch is developed along a linear path to a specified distance to create a 3D form. The cross-section of solid model is drawn in sketcher of solidworks and it is extruded in direction perpendicular to sketching plane. It is used to add or remove material from the given model. You can either select the sketch first or then start the extrude tool, or you can start the extrude tool and then select the sketch. It is also used to create a hole in a given model. Revolve: Revolve is solidwork feature tool which is used to create solid 3D model around an axis. One can resolve the sketch around an axis to add materials to it. Using this feature one can create solid ring, hollow cylinder, pressure vessel, solid and hollow sphere etc.

5.2 CAD Design of components:

 Base

Fig: 5.1 Base Length: 700mm Width: 400mm Height: 200mm Material: MS (mild steel)

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 Bearing Holder

Fig: 5.2 bearing holder P205 Bearing Pedestal Internal Diameter: 25mm Type: Thrust Bearing

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 ACTUAL PROTOTYPE

Fig 5.3 front view of assembly

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Fig 5.4 side view of assembly

Figure 5.5 back view of assembly

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Figure 5.6 top view of assembly

5.5 Manufacturing Process: The following are the various manufacturing process used in mechanical engineering. 1) Primary Shaping Process: The process used for the preliminary shaping of the machine component is known as primary shaping process. 2) Machine Design : The process used for giving final shape to the machine component, according to planned dimensions is known as machining process. The common operation drilling, boring etc. 3) Surface Finishing Process: The process used to provide a good shape surface finish for the Machine components are known as surface finishing processes. The common operation used for the process are polishing, buffing, lapping etc. 4) Joining Process:

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The process used for joining machine components are known as joining process. The common operation used for this process are soldering, brazing, welding etc. 5) Process Affecting Change in Properties: These are intended to import specific properties to material e.g. heat treatment, hot working, cold rolling etc.

5.6 SWOT Analysis:  SWOT Analysis is a useful technique for understanding our Strengths and Weaknesses, and for identifying both the Opportunities open to you and the Threats you face.  SWOT is a strategic planning tool used to evaluate the strengths, weaknesses, opportunities, and threats to a project. It involves specifying the objective of the project and identifying the internal and external factors that are favourable and unfavourable to achieving that objective. The strengths and weaknesses usually arise from within an organization, and the opportunities and threats from external sources.  What makes SWOT particularly powerful is that, with a little thought, it can help you uncover opportunities that you are well-placed to exploit. And by understanding the weaknesses of our project, you can manage and eliminate threats that would otherwise catch you unawares.  More than this, by looking at our self and our competitors using the SWOT framework, we can start to craft a strategy that helps you distinguish our self from your competitors, so that we can compete successfully in your market.

 Advantages of SWOT 

Straightforward and only costs time to do.



Produces new ideas to help take advantage of an organization’s strengths and defends against threats.



Awareness of political and environmental threats allows an organization to have response plans prepared.

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 Disadvantages of SWOT 

May persuade organizations to compile lists rather than think about what is essential to achieving objectives.



Presents lists uncritically and without clear prioritization so, for example, weak opportunities may appear to balance strong threats.



Usually, a simple list and not critically presented.

Figure 5.7 SWOT Analysis  Strengths and Weaknesses: These are the internal factors within an organization. 

Human resources - staff, volunteers, board members, target population



Physical resources - your location, building, equipment



Financial - grants, funding agencies, other sources of income



Activities and processes - programs you run, systems you employ



Past experiences - building blocks for learning and success, your reputation in the community

 Opportunities and Threats: These are external factors stemming from community or societal forces. Government Engineering College, Modasa

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

Future trends in your field or the culture



The economy - local, national, or international



Funding sources - foundations, donors, legislatures



Demographics - changes in the age, race, gender, culture of those you serve or in

5.7 Flow process chart: Sr.

Description

No. FRAME 1

Purchasing square pipe

2

Transfer to cutting shop

3

Cutting of square pipe

4

Transfer to welding

5

Welding operator

6

Inspection

7

Transfer to Drilling

8

Drilling Oration

9

Inspection of Drilling

SHAFT 1

Purchasing cast Iron

2

Transferring to lath shop

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Facing operator

4

Turning operator

5

Inspection

Sr.

Description

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No. CYLINDRICLE BAR

1

Purchasing Iron

2

Transferring to lath shop

3

Facing operator on lath machine

4

Riling Operator on lath machine

5

Inspection

ASSEMBLING

1

To gathering all parts at assembling hall

2

Inspection

4

Assembling of cylinder bar to the frame

5

Inspection

6

Attaching chin drive and welding all parts

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Inspection

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5.8 Advantages: 

The dynamically-self-inflating tyre system would be capable of succeeding as a new product in the automotive supplier industry. It specifically addresses the needs of the consumers by maintaining appropriate tyre pressure conditions for:



Reduced tyre wear



Increased fuel economy up to 15%.



Increased overall vehicle safety



Because such a product does not currently exist for the majority of passenger vehicles, the market conditions would be favourable for the introduction of a selfinflating tyre system.



Through extensive engineering analysis, it has also been determined that the selfinflating tyre system would actually function as desired. In particular, the product would be capable of:



Providing sufficient airflow to the tyre with minimal leakage withstanding the static and dynamic loading exerted on the rotary joints.

5.9 Applications: 

It can be used in military vehicles.



It can be used in emergency vehicles like ambulance, police vehicles and fire vehicles.



It can be used in trucks and trailers.



It can be used in very costly vehicles where maintenance of standard is important.

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COSTING

6.1 Cost Structure: No.

Material

Quantity

Cost (Rs.)

1

Rotary Element

2

6000

2

Mini Compressor

1

1200

3

Tire

2

1200

4

Supporting Structure

5

Pressure Switch

1

1000

6

Metal Plate

-

400

7

Castor Wheel

1

500

8

Bearings With Pedestal

2

440

9

Motor

1

1500

10

Chain Drive

1

500

11

Pipes/Hoses

-

250

12

Pressure Gauge

1

200

TOTAL COST

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CHAPTER-7

Canvas Activity Canvas sheet making activity is one part of the project description about what observation done at our domain. With the help of making different canvas sheet we can explain the problem or the project easily. Following canvas sheets are included in this phase of the project (in 7th semester). 

AEIOU Summary Canvas



Empathy Summary Canvas



Ideation Canvas



Product Development Canvas

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7.1 AEIOU SUMMARY

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AEIOU SUMMARY CANVAS In AEIOU canvas includes five parts of the summary which describe different things about domain observation and that five portions are: 

Activities



Environment



Interaction



Objects



Users

Activities: 

This section indicates the whole activities which are done by the group or team for the making of all details for the project and which activities observed by team at domain. All the basic detail of works related to our project is denoted by the notes in simple word in this activities section. Environment:



As the name this section is about the environment. Which environmental effects are affecting on the project and which activities and problems are solved in different environment is indicate in this section. Different conditions, different weather, etc. Interaction:



This section is indicates the technical and non-technical conversation between the students and other persons which is related to the project is indicating in this section. Objects:

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The components and tools/materials which are use at domain and for making the model of the project is indicate in this section. Users:



The all people who use of implement the model of our project and also domain are call users and they are indicate in this section.

7.2 EMPATHY CANVAS

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EMPATHY MAPPING CANVAS In empathy mapping canvas there are 3 sections are indicate summary of empathy mapping. This canvas is indicates the whole story boarding of the project. There are 3 sections of the sheet are: • Users • Stakeholders • Story boarding USERS: In all world people who actually use this working model of our project are call as users of the project. STAKEHOLDERS: The other people who also use the model or implement the model in the vehicle are call stakeholders. STORY BOARDING: Actually what problem of the project and idea to make the project is found from the story boarding? There are two parts in story boarding which are happy story and sad story. From the happy and sad portion of the story boarding the idea of project is induced. Sad story is about the tragic observation. From the sad story we can find the problem and get the idea that which implements is require for that particular problem. And happy story is defining our project concept.

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7.3 PRODUCT DEVLOPMENT CANVAS

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PRODUCT DEVLOPMENT CANVAS There are following 6 contents are including the product development canvas: • People • Purpose • Product experience • Product functions • Component • Product features PEOPLE: This segment is more focused about the kind of people we have in mind while developing the product and also the people for whom we are resolving the problem. It consists of people of various segments which are vehicle drivers, industry, railways, automobile etc. PURPOSE: This block defines the broad purpose of our product. It also contains the problem sector we want to target broadly or specifically. The purpose of our study is having various elements that we want to target are better shock absorbing capacity, more comfortable ride, safety etc. our main target is safety while driving. PRODUCT EXPERIENCE: In this section the focus is on how the customer feels and their review for our product/service concept. We have mentioned every kind of experience we would want our user to feel, enjoy or avail. It also consists of problems we want to address and how user feels about each of problems. This block is having contains as safety against shock and vibrations or accidents.

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PRODUCT FUNCTIONS: Product functions deliver the product experience. So, converting the product experience into functions for our product/service that should perform to meet the customer experience we have just identified in product experience. Mostly the user experience/needs will be our product functions which are more stability, sustain shock and vibration, more efficient etc. PRODUCT FEATURES: Features power the product functions. We have found product features that will deliver the product functions we have identified which are greater ride quality, uniform contact with road surface etc. COMPONENTS: Components build up the features. So this block contains various components required to accomplish the above mentioned product functions and features which are battery, aluminum core for electromagnet, spring, support rod, dashboard, seat, sensors etc.

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7.4 IDEATION CANVAS

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IDEATION CANVAS SHEET The ideation canvas consists of following points: 

People



Activities



Situation/ Location/ Context



Possible solution

PEOPLE: 

This block comprises distinct people we can think of or we are interested to solve problems for which are automobile manufacturer, engineers, automobile companies etc. ACTIVITIES:



This block comprises the distinct activities performed by the people described in above block which are analysis, design, literature review, patent search, dimensions etc. SITUATION/ LOCATION/ CONTEXT:



Every above mentioned activity can be done in a different situation, location or context. So the locations and places where above mentioned activities performed are transportation vehicles, railways, industry, shock absorber etc. POSSIBLE SOLUTIONS:



This block consists of the objects, technologies or solutions which may be possible outcomes to our idea which are high efficiency, reduction in vibration, comfortable ride etc.

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CHAPTER-8 : BMC CANVAS SHEET

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BMC CANVAS REPORT Customer Segments 

Large scale industry



Automobile cars industry



Emergency vehicles user

Value Proposition 

Better Performance



Modernization



Reduce Human Fatigue



Time reduction

Channels 

Retailer



Consumer



Market



Seller



Ecommerce



Distributor

Customer Relationships

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Free Installation



Service



Discount



Better co-ordination



Feedback



Communication

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Revenue Stream 

Value department



Time reduction



Real Time



Market



Fixed Price



Advertising

Key Activities 

Design



Analysis



Raw material



Manufacturing



Fabrication



Assembly

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Key Resources 

Human



Financial



Raw material

Key Partners 

Design – SAI CAD CENTRE



Raw material – Ambica Tools material, mahalaxmi pneumatics



Manufacturing –



Assembly – AAE Engineering

ARVIND AUTO ENGINEERING, AAA Engineering

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CHAPTER : 9

PERIODIC PROGRESS REPORT (PPR)

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CHAPTER: 10

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PATENT DRAFTING EXERCISE (PDE)

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CONCLUSION

Central tyre inflation systems have many advantageous benefits in the transportation industry. These benefits include, improved vehicle mobility due to the increase in traction when tyre pressures are lowered, improved ride quality and cargo safety due to the reduction in vehicle vibrations when the correct tyre pressure is used for a particular road condition, reduced road maintenance because sediment production is limited and lowered road construction costs, increased fuel efficiency and a considerable increase in the tyre life of vehicles. All these benefits contribute to a considerable cost saving in the overall operation of a transportation vehicle.

11.1 Future Scope: 

As previously mentioned, the main beneficiaries of this advancement in technology that will allow for tyre pressure to be adjusted for driving conditions will be the vehicle owners.



Despite an initial investment in the technology, they will experience a reduction in tyre wear and an increase in fuel economy; both of which will result in saving money in the long run.



It is plausible to say that society as a whole will benefit from the resulting design. The reduction in tyre disposal in landfills and decrease the rate of consumption of natural resources will truly benefit society. Also, the improvement in vehicle safety will benefit all people who drive a vehicle on the roadways.

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11.2 References: Books: 1. Theory of Machine Book by R.S. KHURMI 2. Machine Design Book by V.P. BHANDARI. 3. Automobile Engineering by Dr. Kirpal Singh

Websites: 1. https://en.wikipedia.org 2. http://www.thelibraryofmanufacturing.com/forging.html 3.www.engineeringtoolbox.com

Research Papers: 1. T Pletts, Literature Review on Central Tyre Inflation System July 2006. 2. Kunjan Shinde, Sagar Asari, Vighnesh Nayak, Pranav Kadam and Anand Dalvi (Project on Vehicle Automation) Automatic Tire Inflation System. 3.Tawanda Mushiri, Allan T.Muzhanje, Charles Mbohwa. A Literature review on Design of an automatic tyre pressure inflation for small vehicles.

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