AUTOMATIC PNEUMATIC BRAKING AND

BUMPER SYSTEM
 CHAPTER-1
SYNOPSIS

The technology of pneumatics plays a major role in the field of automation and modern
machine shops and space robots.. The aim is to design and develop a control system based
intelligent electronically controlled automotive bumper activation and automatic braking system
is called AUTOMATIC PNEUMATIC BUMPER AND BRAKING SYSTEM FOR FOUR
WHEELER. This project consists of Ultra-sonic transmitter and receiver circuit, Control Unit,
Pneumatic bumper system and braking system. The Ultra-- sonic sensor senses the obstacle. If
there is any obstacle closer to the vehicle (within 1.5 meter), the control signal is given to the
bumper activation system and also braking system simultaneously. The pneumatic bumper and
braking system is used to protect the man and vehicle.

CHAPTER-2

INTRODUCTION

A.BUMPER
A bumper is a structure attached or integrated to the front and rear of an automobile to absorb
impact in a minor collision, ideally minimizing repair costs. Bumpers also have two safety
functions: minimizing height mismatches between vehicles, and protecting pedestrians from
injury. Modern design practice is for the bumper structure on automobiles to consist of a plastic
cover over a reinforcement bar made of steel, aluminum, fiberglass composite, or plastic.
Specialized bumpers, known as "bull bars" or "roo bars", protect vehicles in rural environments
from collisions with large animals.
However, studies have shown that such bars increase the threat of death and serious injury to
pedestrians in urban environments, because the bull bar is rigid and transmits all force of a
collision to the pedestrian, unlike a bumper which absorbs some force and crumples. In the
European Union, the sale of rigid metal bull bars which do not comply with the relevant
pedestrianprotection safety standards has been banned Bumpers offer protection to other vehicle
components by dissipating the kinetic energy generated by an impact.
This energy is a function of vehicle mass and velocity squared. The kinetic energy is equal to 1/2
the product of the mass and the square of the speed.
In formula form:
KE= The impact force is given by the equation,
F= Where m = mass of the automobile
V = velocity of the automobile and
s = slow down distance
A bumper that protects vehicle components from damage at 5 miles per hour must be four times
stronger than a bumper that protects at 2.5 miles per hour, with the collision energy dissipation
concentrated at the extreme front and rear of the vehicle. Modern theories of vehicle
crashworthiness point in the opposite direction, towards vehicles that crumple progressively. A
completely rigid vehicle might have excellent bumper protection for vehicle components, but
would offer poor occupant safety. Bumpers are increasingly being designed to mitigate injury to
pedestrians struck by cars, such as through the use of bumper covers made of flexible materials.
Front bumpers, especially, have been lowered and made of softer materials, such as foams and
crushable plastics, to reduce the severity of impact on legs.
B.AUTOMATIC BRAKING
Automatic braking is a technology for automobiles to sense an imminent collision with another
vehicle, person or obstacle; or a danger such as a high brake or by applying the brakes to slow
the vehicle without any driver input. Sensors to detect other vehicles or obstacles can include
radar, video, infrared, ultrasonic or other technologies.
Automatic braking by the system after sensing an obstacle can be executed in two modes. In
collision avoidance, the collision is avoided by the automatic braking, but the driver will not be
warned in this type of system. There is a very good chance of wrongly interpreting the signals,
especially in the case of radars or lasers. So this is not so effective method of automatic braking.
In collision mitigation system, the sensors detect the possibility of collision but will not take
immediate action. A warning will be sent to the driver in the form of a signal or a voice message.
There is a threshold safe distance calculated by the system and if the driver fails to respond even
when the vehicle crosses that region, then only brakes will be applied automatically. Many
vehicles are provided with the option of turning on or off the automatic system based on their
surroundings. In some automobiles even though they cannot be completely disabled, they can be
limited to warning the driver about coming obstacle. Even this emergency braking initiates ABS
which helps the driver to retain the control over vehicle without any skidding. Automatic braking
system is only effective if the mode of sensing the obstacles is reliable, or else any kind of false
interpretation may cause a lot of damage.

We have pleasure in introducing our new project “AUTOMATIC

PNEUMATIC BUMPER”, which is fully equipped by IR sensors circuit and Pneumatic
bumper activation circuit. It is a genuine project which is fully equipped and designed for
Automobile vehicles. This forms an integral part of best quality. This product underwent
strenuous test in our Automobile vehicles and it is good.

NEED FOR AUTOMATION:

Automation can be achieved through computers, hydraulics, pneumatics, robotics,

etc., of these sources, pneumatics form an attractive medium for low cost automation.

The main advantages of all pneumatic systems are economy and simplicity. Automation

plays an important role in mass production.

 For mass production of the product, the machining operations decide the

sequence of machining. The machines designed for producing a particular product are

called transfer machines. The components must be moved automatically from the bins to

various machines sequentially and the final component can be placed separately for

packaging. Materials can also be repeatedly transferred from the moving conveyors to the

work place and vice versa.

Nowadays almost all the manufacturing process is being atomized in order to

deliver the products at a faster rate. The manufacturing operation is being atomized for

the following reasons.

 To achieve mass production

 To reduce man power

 To increase the efficiency of the plant

 To reduce the work load

 To reduce the production cost

 To reduce the production time

 To reduce the material handling

 To reduce the fatigue of workers

 To achieve good product quality

  Less Maintenance

1.1 Problem Statement

In conventional vehicles there are different mechanism operated for braking system like

hydraulic, pneumatic, air, mechanical, etc. But all these braking mechanisms receive the signal or

input power directly from the driver so it totally manual operated. When the driver saw the

obstacle or any vehicle in front of his driving vehicle, he was irritated or becomes mazy. Due to

this the driver fails to give the proper input to braking system and proper working is not occurs.

Also the driver may not able to pay the full attention during night travelling so there are many

chances to accidents. After the accident occurs, there is no any provision to minimize the

damages of vehicles. In currently used vehicles generally bumpers used are of rigid types. These

bumpers have specific capacity and when the range of the accidental force is very high then the

bumpers are fails and these force transferred towards the passengers. So this system never

reduces the damage of both vehicle and passengers.

1.2Objectives

•To increase the sureness of braking Application.

•To increase the response time of braking system.

•To improve the pre-crash safety.

•To avoid the percentage of passenger injury by using external vehicle safety.

•To reduce the requirement of internal safety devices like air bags.

1.3Scope
 •This system may be applicable in all types of light vehicles like cars, Rickshaws, Tempos.

•This system also successfully installed in the heavy vehicles like buses, trucks, trailers,etc.

•It able to Increase the sureness in braking system.

•Braking system able to give fast response.

•System able to increase the pre-crash safety.

•System able to provide more safety to the passengers.

•System plays an important role to save human life in road accidents.

•To avoid the percentage of passenger injury by using external vehicle safety.

•To reduce the requirement of internal safety devices like air bags.

CHAPTER-3

LITERATURE SURVEY

SAFETY SYSTEM:

The aim is to design and develop a control system based on pneumatic breaking

system of an intelligent electronically controlled automotive braking system. Based on

this model, control strategies such as an 'antilock braking system' (ABS) and improved

maneuverability via individual wheel braking are to be developed and evaluated.

 There have been considerable advances in modern vehicle braking systems in

recent years. For example, electronically controlled ABS for emergency braking,

electronically controlled hydraulically actuated individual brake-by-wire (BBW) systems

for saloon cars and electronically controlled pneumatically actuated systems for heavy

goods vehicles. The work of recent years shall form the basis of a system design

approach to be implemented. The novelty of the proposed research programmed shall lie

in the design and evaluation of control systems for achieving individual wheel motion

control facilitated by BBW. In the case of BBW the brake pedal is detached from the

hydraulic system and replaced by a 'brake pedal simulator'. The simulator provides an

electrical signal for the electronic control system.

Preliminary modeling and simulation work considers a quarter cars initially

followed by a natural progression to the half car and full four wheel station cases. The

model is to be constructed in modular form thus allowing the replacement / interchange

of the various blocks and their associated technologies. Upon completion of the full

vehicle braking model, sensitivity analyses will be carried out. Once the preliminary

simulation model has been thoroughly benchmarked and existing control system

strategies evaluated, an audit of the technology used is to take place and this will provide

a basis for comparison of iterative technologies / techniques.

The final phase of the new modern vehicle shall include:

 Development of improved ABS control systems

 Development and assessment of an electro-hydraulic-BBW (EH-BBW) system

 Individual wheel braking combined with traction control

 Assessing sensor failure and fault tolerant control system design

 Preliminary studies into an electrically actuated system

 Re-engineering using simplified models.

PNEUMATICS

The word ‘pneuma’ comes from Greek and means breather wind. The word

pneumatics is the study of air movement and its phenomena is derived from the word

pneuma. Today pneumatics is mainly understood to means the application of air as a

working medium in industry especially the driving and controlling of machines and

equipment.

Pneumatics has for some considerable time between used for carrying out the

simplest mechanical tasks in more recent times has played a more important role in the

development of pneumatic technology for automation.

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. When

the pneumatic system is being adopted for the first time, however it wills indeed the

necessary to deal with the question of compressed air supply.

The key part of any facility 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 delivered the air at a high 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.

The compressibility of the air was first investigated by Robert Boyle in 1962 and

that found that the product of pressure and volume of a particular quantity of gas.

The usual written as

PV = C (or) PıVı = P2V2

In this equation the pressure is the absolute pressured which for free is about 14.7

Psi and is of courage capable of maintaining a column of mercury, nearly 30 inches high

in an ordinary barometer. Any gas can be used in pneumatic system but air is the mostly

used system now a days.

CHAPTER-7

COMPONENTS AND DESCRIPTION

SELECTION OF PNEUMATICS:

Mechanization is broadly defined as the replacement of manual effort by

mechanical power. Pneumatics is an attractive medium for low cost mechanization

particularly for sequential or repetitive operations. Many factories and plants already

have a compressed air system, which is capable of providing both the power or energy
requirements and the control system (although equally pneumatic control systems may be

economic and can be advantageously applied to other forms of power).

The main advantages of an all-pneumatic system are usually economy and

simplicity, the latter reducing maintenance to a low level. It can also have out standing

advantages in terms of safety.

PNEUMATIC COMPONENTS AND ITS DESCRIPTION

The pneumatic bearing press consists of the following components to fulfill the

requirements of complete operation of the machine.

1) DOUBLE ACTING PNEUMATIC CYLINDER

2) SOLENOID VALVE

3) FLOW CONTROL VALVE

4) IR SENSOR UNIT

5) WHEEL AND BRAKE ARRANGEMENT

6) PU CONNECTOR, REDUCER, HOSE COLLAR

7) STAND

8) SINGLE PHASE INDUCTION MOTOR

A. DOUBLE ACTING PNEUMATIC CYLINDER

 The cylinder is a Double acting cylinder one, which means that the air pressure operates
forward and backward strokes. The air from the compressor is passed through the 3/2
solenoid valve which controls the pressure to required amount by adjusting its knob. A
pressure gauge is attached to the air storage tank for showing the pressure. Figure
1.Double Acting Cylinder TECHNICAL DATA: Double acting pneumatic cylinder stroke
length-100 mm and 50 mm, 100 mm cylinder is used for bumper actuation and 50 mm
cylinder is used for braking arrangement
CYLINDER TECHNICAL DATA:
DOUBLE ACTING CYLINDER SPECIFICATIONS
Parameters Cylinder 1
Working pressure 0-10 bar
Stroke length 125 mm
Rod diameter 16mm
Piston Rod:
M.S. hard Chrome plated

Seals:
Nitrile (Buna – N) Elastomer

End Covers:
Cast iron graded fine grained from 25mm to 300mm

Piston:
-Aluminium.

Media:
-Air.

Temperature Range:
0^c to 85^c
Parts of Pneumatic Cylinder

Piston:

The piston is a cylindrical member of certain length which reciprocates inside the

cylinder. The diameter of the piston is slightly less than that of the cylinder bore diameter

and it is fitted to the top of the piston rod. It is one of the important parts which convert

the pressure energy into mechanical power.

The piston is equipped with a ring suitably proportioned and it is relatively soft

rubber which is capable of providing good sealing with low friction at the operating

pressure. The purpose of piston is to provide means of conveying the pressure of air

inside the cylinder to the piston of the oil cylinder.

Generally piston is made up of

 Aluminium alloy-light and medium work.

 Brass or bronze or CI-Heavy duty.

 The piston is single acting spring returned type. The piston moves forward when

the high-pressure air is turned from the right side of cylinder.

The piston moves backward when the solenoid valve is in OFF condition. The

piston should be as strong and rigid as possible. The efficiency and economy of the

machine primarily depends on the working of the piston. It must operate in the cylinder

with a minimum of friction and should be able to withstand the high compressor force

developed in the cylinder and also the shock load during operation.

The piston should posses the following qualities.

a. The movement of the piston not creates much noise.

b. It should be frictionless.

c. It should withstand high pressure.

Piston Rod

The piston rod is circular in cross section. It connects piston with piston of other

cylinder. The piston rod is made of mild steel ground and polished. A high finish is

essential on the outer rod surface to minimize wear on the rod seals. The piston rod is
connected to the piston by mechanical fastening. The piston and the piston rod can be

separated if necessary.

One end of the piston rod is connected to the bottom of the piston. The other end

of the piston rod is connected to the other piston rod by means of coupling. The piston

transmits the working force to the oil cylinder through the piston rod. The piston rod is

designed to withstand the high compressive force. It should avoid bending and withstand

shock loads caused by the cutting force. The piston moves inside the rod seal fixed in the

bottom cover plate of the cylinder. The sealing arrangements prevent the leakage of air

from the bottom of the cylinder while the rod reciprocates through it.

Cylinder Cover Plates

The cylinder should be enclosed to get the applied pressure from the compressor

and act on the pinion. The cylinder is thus closed by the cover plates on both the ends

such that there is no leakage of air. An inlet port is provided on the top cover plate and an

outlet ports on the bottom cover plate. There is also a hole drilled for the movement of

the piston.
 The cylinder cover plate protects the cylinder from dust and other particle and

maintains the same pressure that is taken from the compressor. The flange has to hold the

piston in both of its extreme positions. The piston hits the top plat during the return

stroke and hits the bottom plate during end of forward stroke. So the cover plates must

be strong enough to withstand the load.

Cylinder Mounting Plates:

It is attached to the cylinder cover plates and also to the carriage with the help of

‘L’ bends and bolts.

2. SOLENOID VALVE WITH CONTROL UNIT:

The directional valve is one of the important parts of a pneumatic system.

Commonly known as DCV, this valve is used to control the direction of air flow in the

pneumatic system. The directional valve does this by changing the position of its internal

movable parts.

This valve was selected for speedy operation and to reduce the manual effort and

also for the modification of the machine into automatic machine by means of using a

solenoid valve. A solenoid is an electrical device that converts electrical energy into
straight line motion and force. These are also used to operate a mechanical operation

which in turn operates the valve mechanism. Solenoids may be push type or pull type.

The push type solenoid is one in which the plunger is pushed when the solenoid is

energized electrically. The pull type solenoid is one is which the plunger is pulled when

the solenoid is energized.

The name of the parts of the solenoid should be learned so that they can be

recognized when called upon to make repairs, to do service work or to install them.

Parts of a Solenoid Valve

1. Coil

The solenoid coil is made of copper wire. The layers of wire are separated by

insulating layer. The entire solenoid coil is covered with an varnish that is not affected by

solvents, moisture, cutting oil or often fluids. Coils are rated in various voltages such as

115 volts AC, 230 volts AC, 460 volts AC, 575 Volts AC, 6 Volts DC, 12 Volts DC, 24

Volts DC, 115 Volts DC & 230 Volts DC. They are designed for such frequencies as 50

Hz to 60 Hz.

2. Frame

The solenoid frame serves several purposes. Since it is made of laminated sheets,

it is magnetized when the current passes through the coil. The magnetized coil attracts
the metal plunger to move. The frame has provisions for attaching the mounting. They

are usually bolted or welded to the frame. The frame has provisions for receivers, the

plunger. The wear strips are mounted to the solenoid frame, and are made of materials

such as metal or impregnated less fiber cloth.

3. Solenoid Plunger

The Solenoid plunger is the mover mechanism of the solenoid. The plunger is

made of steel laminations which are riveted together under high pressure, so that there

will be no movement of the lamination with respect to one another. At the top of the

plunger a pin hole is placed for making a connection to some device. The solenoid

plunger is moved by a magnetic force in one direction and is usually returned by spring

action. Solenoid operated valves are usually provided with cover over either the solenoid

or the entire valve. This protects the solenoid from dirt and other foreign matter, and

protects the actuator. In many applications it is necessary to use explosion proof

solenoids.
Technical Data:

Size : ¼”
Pressure : 0 to 7 kg / cm2
Media : Air
Type : 5/2
Applied Voltage : 12VDC

3. FLOW CONTROL VALVE:

1. Technical Data:

Size : ¼”
Pressure : 0 to 10 kg / cm2
Media : Air

(b) Purpose:

This valve is used to speed up the piston movement and also it acts as an one – way

restriction valve which means that the air can pass through only one way and it can’t

return back. By using this valve the time consumption is reduced because of the faster

movement of the piston.

 4. Ultrasonic sensor

The ultrasonic sensor is used to sense the obstacle and measure the distance between the vehicle

and the obstacle. The ultrasonic sensor used is Ultrasonic Ranging Module HC - SR04.

Ultrasonic ranging module HC - SR04 provides 2cm - 400cm non-contact measurement

function, the ranging accuracy can reach to 3mm. The modules includes ultrasonic transmitters,

receiver and control circuit. Figure 8. Ultrasonic sensor Electric Parameters are as follows

TABLE IV ELECTRIC PARAMETERS OF ULTRASONIC

Working Voltage DC 5 V
Working Current 15mA
Working Frequency 40Hz
Max Range 4m
Min Range 2cm
Measuring Angle 15 degree
Trigger Input Signal 10uS TTL pulse
Echo Output Signal Input TTL lever signal
and the range in
proportion
Dimension 45*20*15mm
c. Relay
The relay module is an electrically operated switch that allows you to turn on or off a

circuit using voltage and/or current much higher than a microcontroller could handle.

There is no connection between the low voltage circuit operated by the microcontroller

and the high power circuit. The relay protects each circuit from each other. The each

channel in the module has three connections named NC, COM, and NO. Depending on

the input signal trigger mode, the jumper cap can be placed at high level effective mode

which „closes‟ the normally open (NO) switch at high level input and at low level

effective mode which operates the same but at low level input. Working voltage is 5V and

current is 10A

AT NORMAL CONDITION:

The IR transmitter sensor is transmitting the infrared rays with the help of 555 IC

timer circuit. These infrared rays are received by the IR receiver sensor. The Transistor

T1, T2 and T3 are used as an amplifier section. At normal condition Transistor T5 is OFF

condition. At that time relay is OFF, so that the vehicle running continuously.

AT OBSTACLE CONDITION:

At Obstacle conditions the IR transmitter and IR receiver, the resistance across the

Transmitter and receiver is high due to the non-conductivity of the IR waves. So the
output of transistor T5 goes from OFF condition to ON stage. In that time the relay is ON

position. In that time, the solenoid valve is on so that the vehicle stops.

5. WHEEL AND BRAKING ARRANGEMENT:

The simple wheel and braking arrangement is fixed to the frame stand. Near the

brake drum, the pneumatic cylinder piston is fixed.

6. PU CONNECTIORS, REDUCER AND HOSECOLLAR:

In our pneumatic system there are two types of connectors used; one is the hose

connector and the other is the reducer. Hose connectors normally comprise an adapter

(connector) hose nipple and cap nut. These types of connectors are made up of brass or

Aluminium or hardened steel. Reducers are used to provide inter connection between two

pipes or hoses of different sizes. They may be fitted straight, tee, “V” or other

configurations. These reducers are made up of gunmetal or other materials like hardened

steel etc.

7. STAND:

This is a supporting frame and made up of mild steel.

 CHAPTER-9

WORKING OPERATION

The impartant components of our project are,

Control Unit with Power supply

Solenoid Valve

Flow control Valve

Air Tank (Compressor)

\
 Figure 9. Block diagram of our project

The ultrasonic circuit is to transmit the ultrasonic rays. If any obstacle is there in a path, the ultra-
sonic rays are reflected. These reflected ultrasonic rays are received by the receiver. The receiver
circuit receives the reflected rays and giving the control signal to the control circuit. The control
circuit is used to activate the solenoid valve. If the solenoid valve is activated, the compressed air
passes to the Single Acting Pneumatic Cylinder. The compressed air activates the pneumatic
cylinder and moves the piston rod forward. Thus the bumper is actuated. When the solenoid
valve gets actuated the compressed air also goes to the small single acting pneumatic cylinder
and actuates it. If the piston moves forward, then piston rod which is connected to the lever of
the hydraulic disc brake pushes and hence the brake is applied. The braking arrangement is used
to brake the wheel gradually or suddenly due to the piston movement. The braking speed is
varied by adjusting the valve is called flow control valve. The compressed air flow through the
polyurethane tube to the flow control valve. The flow control valve is connected to the solenoid
valve.
3D model of automatic pneumatic bumper and braking system
 Chapter- 6
DESIGN

Design consists of application of scientific, principles, technical information and

imagination for development of new or improvised machine or mechanism to perform a specific
with maximum economy & efficiency.
Hence a careful design approach has to be adopted. The total design work has been split
up into two parts;
 System design
 Mechanical Design
System design mainly concerns the various physical constraints and ergonomics, space
requirements, arrangement of various components on main frame at system, man + machine
interaction, No. of controls, position of controls, working environment of machine, chances of
failure, safety, measures to be provided, servicing aids, ease of maintenance, scope of
Improvement, weight of machine from ground level, total weight of machine and a lot more.
In mechanical design the components are listed down and stored on the basis of their
procurement, design in two categories namely,
 Designed Parts
 Parts to be purchased
For designed parts detached design is done & distinctions thus obtained are compared to
next highest dimensions which are readily available in market. This amplifies the assembly as
well as postproduction servicing work. The various tolerances on the works are specified. The
process charts are prepared and passed on to the manufacturing stage.
The parts which are to be purchased directly are selected from various catalogues &
specified so that anybody can purchase the same from the retails shop with given specifications.

6.1. SYSTEM DESIGN:

In system design we mainly concentrated on the following parameters:-

6.1.1. System Selection Based on Physical Constraints:

 While selecting any machine it must be checked whether it is going to be used in a large
– scale industry or a small scale industry. In our case it is to be used by a small scale industry .So
space is a major constrain. The system is to be very compact so that it can be adjusted to corner
of a room.
The mechanical design has direct norms with the system design. Hence the foremost job is to
control the physical parameters, so that the distinctions obtained after mechanical design can be
well fitted into that.

6.1.2. Arrangements of Various Components:

Keeping into view the space restrictions the components should be laid such that their
easy Removal or servicing is possible. More over every component should be easily seen none
should be hidden. Every possible space is utilized in components arrangements.

6.1.3. Components of System:

As already stated the system should be compact enough so that it can be accommodated
at a corner of a room. All the moving parts should be well closed & compact. A compact system
design gives a high weighted structure which is desired.
Man Machine Interaction
The friendliness of a machine with the operator that is an important criteria of design. It
is the application of anatomical & psychological principles to solve problems arising from Man –
Machine relationship. Following are some of the topics included in this section. Design of foot
lever Energy expenditure in foot & hand operation Lighting condition of machine.

6.1.4. Chances of Failure:

The losses incurred by owner in case of any failure are important criteria of design.
Factor safety while doing mechanical design is kept high so that there are less chances of failure.
Moreover periodic maintenance is required to keep unit healthy.

6.1.5. Servicing Facility:

 The layout of components should be such that easy servicing is possible. Especially those
components which require frequents servicing can be easily disassembled. Scope of Future
Improvement Arrangement should be provided to expand the scope of work in future.
Such as to convert the machine motor operated; the system can be easily configured to
required one. The die & punch can be changed if required for other shapes of notches etc.

6.1.6. Height of Machine from Ground:

For ease and comfort of operator the height of machine should be properly decided so
that he may not get tried during operation. The machine should be slightly higher than the waist
level, also enough clearance should be provided from the ground for cleaning purpose.

6.1.7. Weight of Machine:

The total weight depends upon the selection of material components as well as the
dimension of components. A higher weighted machine is difficult in Transportation & in case of
major breakdown; it is difficult to take it to workshop because of more weight.

6.1.8. Mechanical Design:

Mechanical design phase is very important from the view of designer as whole success of
the project depends on the correct design analysis of the problem.
Many preliminary alternatives are eliminated during this phase Designer should have
adequate knowledge above physical properties of material, loads stresses, deformation, and
failure. Theories and wear analysis. He should identify the external and internal force acting on
the machine parts.
This force may be classified as;
1] Dead weigh forces
2] Friction forces
3] Inertia forces
4] Centrifugal forces
5] Forces generated during power transmission etc.
Designer should estimate these forces very accurately by using design equations. If he
does not have sufficient information to estimate them he should make certain practical
assumptions based on similar conditions. This will almost satisfy the functional needs.
Assumptions must always be on the safer side.
Selection of factors of safety to find working or design stress is another important step in
design of working dimensions of machine elements. The corrections in the theoretical stress
value are to be made according in the kinds of loads, shape of parts & service requirements.
Selection of material should be made according to the condition of loading shapes of
products environments conditions & desirable properties of material.
Provision should be made to minimize nearly adopting proper lubrications methods.
In, mechanical design the components are listed down & stored on the basis of their
procurement in two categories.
 Design parts
 Parts to be purchased
For design parts a detailed design is done & designation thus obtain are compared to the
next highest dimension which is ready available in market.
This simplification the assembly as well as post production service work. The various
tolerances on the work are specified. The processes charts are prepared & passed on to the work
are specified.
The parts to be purchased directly are selected from various catalogues & specification so
that anybody can purchase the same from retail shop with the given specifications.

A. STOPPING DISTANCE CALCULATION

The total stopping distance of a vehicle is made up of 4 components. They are,

Human Perception Time

Human Reaction Time

Vehicle Reaction Time and

Vehicle Braking Capability

The human perception time is how long the driver takes to see the hazard, and the brain realize it

is a hazard requiring an immediate reaction. This perception time can be as long as ¼ to ½ a

second. Human Reaction Time Once the brain realizes danger, the human reaction time is how

long the body takes to move the foot from accelerator to brake pedal. Again this reaction time

can vary from ¼ - ¾ of a second. Once the brake pedal is applied there is the vehicles reaction

time which depends on the brake pedal free-play, hydraulic properties of the brake fluid and

working order of the braking system. Since it is a automatic braking system the time taken to

actuate the solenoid valve after sensing the obstacle should be taken into account. This time is

called as the system response time. The response time of our system is 1msec.so the distance

travelled in 1msec is very less hence it is ignored

Total stopping distance = Human perception distance human reaction distance braking

distance + distance covered in 1msec

Braking distance,

Braking = m

Where, v = Velocity before applying brakes

µ = coefficient of friction = 0.7 (for dry surfaces)

g = acceleration due to gravity (9.81 )

Braking =

Braking distance, DBraking = 1.26 m

Here the human perception time and human reaction time

are equal to „zero‟ because it is an automatic braking system.

Total stopping distance = 1.26 m

 Total braking distance = 1.26 Bumper actuation

length

= 1.26 0.100

= 1.36 m

Hence the sensors sensing range is set at 1.5 m

B.IMPACT FORCE CALCULATION

Mass of the vehicle = 22 kg

Velocity of the vehicle = 15 = 4.167

Braking distance = 1.26 m

By motion equation

2as =v2

Where, v = final velocity

u = initial velocity
a = acceleration &
s = braking distance
2
a = 6.89
Force, F = mass× acceleration
= 22× (-6.89)
F = 151.58 N
F = 151.58 N
 DESIGN & ANALYSIS PNEUMATIC CYLINDER:
i) Design of Piston rod:
Load due to air Pressure.
Diameter of the Piston (d) = 40 mm
Pressure acting (p) = 6 kgf/cm²
Material used for rod = C 45
Yield stress (σy) = 36 kgf/mm²
Assuming factor of safety=2
Force acting on the rod (P)= Pressure x Area
= p x (Πd² / 4)
=6 x {(Π x 4²) / 4}
p = 73.36 Kgf

Design Stress(σy) = σy / F0 S
= 36 / 2 = 18 Kgf/mm²
= P / (Π d² / 4)
∴ d = √ 4 p / Π [σy]
= √ 4 x 75.36 / {Π x 18}
= √ 5.33 = 2.3 mm

∴ Minimum diameter of rod required for the load=2.3 mm

We assume diameter of the rod = 15 mm

ii) Design of cylinder thickness:

Material used = Cast iron
Assuming internal diameter of the cylinder= 40 mm
Ultimate tensile stress = 250 N/mm² = 2500 gf/mm²
Working Stress =Ultimate tensile stress / factor of safety
Assuming factor of safety= 4
Working stress ( ft ) = 2500 / 4
= 625 Kgf/cm²
According to ‘LAMES EQUATION’
Minimum thickness of cylinder ( t ) =
Ri {√ (ft + p) / (ft – p ) -1 }
Where, Ri = inner radius of cylinder in cm

ft = Working stress (Kgf/cm²)

p = Working pressure in Kgf/cm²
∴ Substituting values we get,
t = 2.0 {√ (625 + 6) / (625 – 6) -1}
t = 0.019 cm = 0.19 mm
We assume
We assume Thickness of cylinder = 2.5 mm
Inner diameter of barrel = 40 mm
Outer diameter of barrel = 40 + 2t
= 40 + (2 x 2.5)
= 45 mm
iii) Length of piston rod:
Approach stroke = 125 mm
Length of threads = 2 x 20 = 40mm
Extra length due to front cover = 12 mm
Extra length of accommodate head = 20 mm
Total length of the piston rod = 160 + 40 + 12 + 20
= 232 mm
By standardizing, length of the piston rod = 125 mm
 If the solenoid valve is activated, the compressed air passes to the Single Acting

Pneumatic Cylinder. The compressed air activate the pneumatic cylinder and moves the

piston rod.

If the piston moves forward, then the breaking arrangement activated. The

breaking arrangement is used to break the wheel gradually or suddenly due to the pistion

movement. The breaking speed is varied by adjesting the valve is called “FLOW

CONTROL VALVE”.

In our project, we have to apply this breaking arrangement in one wheel as a

model. The compressed air drawn from the compressor in our project. The compressed

air floe through the Polyurethene tube to the flow control valve. The flow control valve is

connected to the solenoid valve as mentioned in the block diagram.

CHAPTER-11
 APPLICATIONS AND ADVANTAGES

APPLICATIONS

For automobile application

Industrial application

ADVANTAGES

Free from wear adjustment.

Less power consumption
It gives simplified very operation.
Installation is simplified very much

DISADVANTAGES

Additional cost is required to install this arrangement in the

vehicle .
 CHAPTER-12

LIST OF MATERIALS

Sl. No. PARTS Qty.

i. Double Acting Pneumatic Cylinder 1
ii. Flow Control Valve 1
iii. Wheel 1
iv. Solenoid Valve 1
vi. Sensor Unit 1
viii. Polyethylene Tube -
ix. Hose Collar and Reducer -
x Stand (Frame) 1

CHAPTER-13

COST ESTIMATION

1. MATERIAL COST:

Sl. No. PARTS Qty. Amount (Rs)

i. Double Acting Pneumatic Cylinder 1
ii. Flow Control Valve 1
iii. Wheel 1
iv. Solenoid Valve 1
 vi. Sensor Unit 1
viii. Polyethylene Tube -
ix. Hose Collar and Reducer -
x Stand (Frame) 1

2. LABOUR COST

LATHE, DRILLING, WELDING, GRINDING, POWER HACKSAW, GAS CUTTING:

Cost =

3. OVERHEAD CHARGES

The overhead charges are arrived by “Manufacturing cost”

Manufacturing Cost = Material Cost + Labour cost

=
=

Overhead Charges = 20% of the manufacturing cost

=

TOTAL COST

Total cost = Material Cost + Labour cost + Overhead Charges

=
 =

Total cost for this project =

CHAPTER-14

CONCLUSION

This project work has provided us an excellent opportunity and experience, to use

our limited knowledge. We gained a lot of practical knowledge regarding, planning,

purchasing, assembling and machining while doing this project work. We feel that the

project work is a good solution to bridge the gates between institution and industries.

We are proud that we have completed the work with the limited time successfully.

The AUTOMATIC PNEUMATIC BRAKING AND BUMPER SYSTEM is working

with satisfactory conditions. We are able to understand the difficulties in maintaining the

tolerances and also quality. We have done to our ability and skill making maximum use

of available facilities.

In conclusion remarks of our project work, let us add a few more lines about our

impression project work. Thus we have developed an “AUTOMATIC PNEUMATIC

BRAKING AND BUMPER SYSTEM” which helps to know how to achieve low cost
automation. The application of pneumatics produces smooth operation. By using more

techniques, they can be modified and developed according to the applications.

BIBLIOGRAPHY

1. G.B.S. Narang, “Automobile Engineering”, Khanna Publishers, Delhi, 1991,

pp 671.

2. William H. Crowse, “Automobile Engineering”.

3. Donald. L. Anglin, “Automobile Engineering”.

4. Pneumatic Control System----Stroll & Bernaud, Tata Mc Graw Hill

Publications, 1999.

5. Pneumatic System----Majumdhar, New Age India International (P) Ltd

Publishers, 1997.

Web sites:

www. Profc.udec.cl/~gabriel/tutorials.com

www.carsdirect.com/features/safetyflatures

www.hwysafety.org