PNEUMATIC STEERING GEAR

PROJECT REPORT
Submitted by
S.NO NAME OF THE CADET REG.NO
1 DIYYALA NITHEESH CHOWDARY AME19014
2 GOVIND V AME19017
3 SHAMEEM THOUFEEQUE AME19030
4 VIGNESH AME19017
5 AJAY G AME19157L
6 RYVAN.PS AME19251L
7 JUWEL SOMAN AME19270L
8 JESTOSAJI AME19271L

In partial fulfillment of the of the award of the degree of

BACHELOR OF ENGINEERING
IN
MARINE ENGINEERING

AMET UNIVERSITY : CHENNAI 603112

 BONAFIDE CERTIFICATE
This is to certify that project entitled “PEUNAMATIC STEERING GEAR”
is the bonafide work carried out by students of AMET UNIVERSITY,
KANATHUR (CHENNAI) during the year 2022-2023 for the partial
fulfillment of the requirements for the award of degree of Bachelor
of Marine Engineering.

SIGNATURE SIGNATURE
Prof C/E BHOOPATHY BHASKARAN C/E Mr.K.R. CHIDAMBARAM
HEAD OF THE DEPARTMENT SUPERVISOR
Department of Marine Engineering Department of Marine Engineering
AMET Deemed to be University AMET Deemed to be University
Chennai. Chennai.

Submitted for B.E. Degree Viva-Voice examination held at AMET Deemed to be

university, Chennai on ………………………

INTERNAL EXAMINER EXTERNAL EXAMINER

 ABSTRACT
Hydraulic steering gear is the most commonly used
steering gear in ships and it has many problems
associated with it and the major problem that occurs is
oil leakages and port state controls have very strict
policy of zero leakage from ships steering gear. Many
ships were imposed with fine and detained due to such
faults pointed out during inspection. And it also need
continuous power supply from the ships to operate the
pump and it also need to be connected with the
emergency switch board so in order to avoid these
problems and make the steering more efficient, we are
using pneumatic steering gear and it is not affected by
ship’s power supply variations and no heat generated
and hence non risk of fire and doesn’t have complex
piping system like hydraulic steering gear it has simple
control air piping system with the separate installation
of air compressor and an air bottle. This steering gear
can be totally isolated from rest of the machinery
onboard ship.
 ACKNOWLEDGEMENT

Inspiration to achieve, encouragement when things go against your

expectations, and proper guidance in the right directions are
indispensable for the success of any project and we are not an
expectation to that we have received these in excess from all corners
from various people. We are indebted to submit our gratitude to
them.
We thank Col. Dr. G. THIRUVASAGAM, Vice-Chancellor of AMET
(Deemed to be University) for extending his generous hand in
providing the best of their sources in the AMET.
Dr. M. JAYAPRAKASHVEL, the esteemed Registrar of our AMET
(Deemed to be University) has been a constant source of motivation
for all staff and students of the AMET. We are very grateful to him.
We are privileged to express our deep gratitude to Prof. C/E
BHASKARAN, Principal DGS Courses for his continuous motivation
and support in completing our project work.
We have no words to express our thanks to our supervisor C/E K.R
CHIDAMBARAM, Director, for his keen interest, guidance inspiration
and valuable suggestion during the course of our project
We are honored to express our thanks to our beloved Head of the
Department Prof. Dr. R. RAJAVEL, who always served as a source of
inspiration and encouraged us throughout the project and also
contributed his valuable suggestions, instruction and in doing this
project. We express our profound gratitude to the teaching and non-
teaching staff of the Marine Engineering Department for their
valuable suggestion during our project work.
 TABLE OF CONTENTS
S.NO TITLE PG.NO
1 ABSTRACT 3
2 ACKNOWLEDGEMENT 4
3 TABLE OF CONTENTS 5
4 INTRODUCTION 6
5 MODEL AND MATERIAL USED 7
5.1 Pneumatic cylinder 7
5.2 Directional solenoid valve 11
5.3 Flow control valve 13
5.4 Connectors and hoses 14
5.5 Gear wheel and shaft 15
5.6 DC air compressor 18
5.7 Battery 23
5.8 Rudder 24
6 PROJECT PICTURES 25
7 BREAKDOWN OF PROJECT 26
EXPENDITURE
8 CONCLUSION 27
 INTRODUCTION

The project is about operation of steering

gear by using compressed air instead of
hydraulic oil like the most steering gears.
The arrangements are made in a such a way
that the compressed air from a dc compressor
is utilized to change the rudder position
according to requirement and in actual ships
we can have air bottle arrangement so the
compressed air can be stored and used during
emergency situations to steer the ship
without depending on the ship,s power
supply and there will be much usage of oil
eliminating the risk of oil leakage from
steering gear.
It has simple piping system easy to operate
and easy to repair in case of damage and has
low maintenance.
 MODEL AND MATERIAL USED
1.PNEUMATIC CYLINDER:

The cylinder is a double acting cylinder one, which means that the air

pressure operates alternatively (forward and backward). The air from the

compressor is passed through the regulator which controls the pressure to

required amount by adjusting its knob. A pressure gauge is attached to the

regulator for showing the line pressure.

Then the compressed air is passed through the directional control valve

for supplying the air alternatively to either sides of the cylinder. Two hoses

take the output of the directional control valve and they are attached to two

ends of the cylinder by means of connectors. One of the outputs from the

directional control valve is taken to the flow control valve from taken to the

cylinder.

Pneumatic cylinder

An air cylinder is an operative device in which the state input energy of

compressed air i.e. pneumatic power is converted in to mechanical output

power, by reducing the pressure of the air to that of the atmosphere.

TYPES:

1.Single stage single acting cylinder

2.Double stage double acting cylinder

a) Single acting cylinder

Single acting cylinder is only capable of performing an operating

medium in only one direction. Single acting cylinders equipped with one inlet

for the operating air pressure, can be production in several fundamentally

different designs.

Single cylinders develop power in one direction only. Therefore no

heavy control equipment should be attached to them, which requires to be

moved on the piston return stoke single action cylinder requires only about

half the air volume consumed by a double acting for one operating cycle.

B) Double acting cylinders :

A double acting cylinder is employed in control systems with the

full pneumatic cushioning and it is essential when the cylinder itself is required

to retard heavy messes. This can only be done at the end positions of the

piston stock. In all intermediate position a separate externally mounted

cushioning derive most be provided with the damping feature.

 The normal escape of air is out off by a cushioning piston before the end

of the stock is required. As a result the sit in the cushioning chamber is again

compressed since it cannot escape but slowly according to the setting made on

reverses. The air freely enters the cylinder and the piston stokes in the other

direction at full force and velocity.

CYLINDER TECHNICAL DATA:

Barrel:

It is made of cold drawn aluminimum honed to 25mm.

Piston Rod:

M.S. hard Chrome plate

Seals:

Nitrile (Buna – N) Elastomer

End Covers:

Cast iron graded fine grained from 25mm to 300mm

Cast iron graded fine grained from 25mm to 300mm

Piston: Aluminium.
Media: Air

Temperature Range:

0^c to 85^c

Cushions:

Adjustable standard - 400mm bore and above.

 2.DIRECTIONAL CONTROL VALVES:

Directional control valves control the way the air passes and used for

controlling the commencement, termination and direction of air flow.

Depending on the number of paths the air is allowed to take, directional valves
are termed as two way, three way, and four way or multi way valves. The
different number of ways by means the number of controlled connections of
the valve, inlet connections to the compressed air supply. The Outlet
connection is given to the air consumer and exhaust connection is given to the
atmosphere.
TYPES:

1. 3/2 Directional control valve

2. 4/2 Directional control valve

3. 4/3 Directional control valve

4. 5/2 Directional control valve

5. 5/3 Directional control valve

Technical Data:

Size : ¼”

Pressure : 0 to 10 kg / cm2

Media : Air

To control the to and fro motion of cylinder, the fluid energy has to be

regulated, controlled and reversed with a predetermined sequence in a

pneumatic system.

Similarly one may have to control the quantity of pressure and flow rate

to generate the desired level of force and speed of actuators. To achieve these

functions, valves are used. Valves are fluid power elements used for controlling

and regulating the working medium.

The main functions of the valves are,

Start and stop the fluid energy

Control the direction of flow of compressed air

Control the flow rate of the fluid

Control the pressure rating of the fluid

 3.FLOW CONTROL VALVE

In any fluid power circuit, flow control valve is used to control the speed

of the actuator. The floe control can be achieved by varying the area of

flow through which the air in passing.

When area is increased, more quantity of air will be sent to actuator as a result

its speed will increase. If the quantity of air entering into the actuator is

reduced, the speed of the actuator is reduced.

 4.CONNECTORS

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 Aliminium 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.
 5.GEAR WHEEL AND SHAFT

The gear wheel and shaft are connected together to convert the piston

movement to the rudder movement

Design of shaft

SPUR GEAR:

No. of Teeth (N) = 50

Diameter Pitch (DP) = 18

PCD = (N/DP) x @%.$

= (50 / 18 ) x 25.4

= 70.56 Mm

Outer Diameter (OD) = { ( N+2 0 ) / DP } 25

= 25.4

= { ( 50+2 ) / 18 } x

25.4

= 73.38 mm

Tooth thickness = ( 1.5708 / DP ) x

= 25.4
 = 2.22mm

Radius of fillet = 1 1/3 x Clearance

= 4/3 x 0.222

= 0.296 mm

Index = 40 / N

= 40 / 50

Working Depth = ( 2 / DP ) x 25.4

= ( 2 / 18 ) x 25.4

= 2.822 mm
Basic design of shaft:

Shaft length = 25cm

Connecting rod length = 15cm

Shaft diameter = 50mm

 6.DC AIR COMPRESSOR

An air compressor is a pneumatic device that converts power (using

an electric motor, diesel or gasoline engine, etc.) into potential energy stored

in pressurized air (i.e., compressed air). By one of several methods, an air

compressor forces more and more air into a storage tank, increasing the

pressure. When the tank's pressure reaches its engineered upper limit, the air

compressor shuts off. The compressed air, then, is held in the tank until called

into use. The energy contained in the compressed air can be used for a variety

of applications, utilizing the kinetic energy of the air as it is released and the

tank depressurizes.

When tank pressure reaches its lower limit, the air compressor turns on

again and re-pressurizes the tank. An air compressor must be differentiated

from a pump because it works for any gas/air, while pumps work on a liquid.

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.
SELECTION OF PNEUMATICS

Mechanization is broadly defined as the replacement of manual effort by

mechanical power. Pneumatic 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 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 advantage of an all pneumatic system are usually economic

and simplicity the latter reducing maintenance to a low level. It can also have

out standing advantages in terms of safety.

PRODUCTION OF COMPRESSED AIR

Pneumatic systems operate on a supply of compressed air, which must

be made available, in sufficient quantity and pressure to suit the capacity of

the system. When 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.

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. Compressor may be

classified in two general types.

1. Positive displacement compressor.

2. Turbo compressor

Positive displacement compressors are most frequently employed for

compressed air plant and have proved highly successful and supply air

for pneumatic control application.

The types of positive compressor

1. Reciprocating type compressor

2. Rotary type compressor

Turbo compressors are employed where large capacity of air required at

low discharge pressures. They cannot attain pressure necessary for

 pneumatic control application unless built in multistage designs and are

seldom encountered in pneumatic service.

RECIPROCATING COMPRESSORS

Built for either stationary (or) portable service the reciprocating

compressor is by far the most common type. Reciprocating compressors lap be

had is sizes from the smallest capacities to deliver more than 500 m³/min. In

single stage compressor, the air pressure may be of 6 bar machines discharge

of pressure is up to 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 preference 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
 7. BATTERY

We have used a 12v 7Amph battery to supply power to the control panel
(pump, sensor, solenoid valves)
BATTERY DETAILS:
Brand - Exide
Voltage – 12v
Dimensions – 16.1*10.4*7.5 cm
Weight - 9 kg
 8.RUDDER
A rudder is a primary control surface used to steer a ship, boat, submarine,
hovercraft, aircraft, or other vehicle that moves through a fluid medium
(generally air or water). On an aircraft the rudder is used primarily to counter
adverse yaw and p-factor and is not the primary control used to turn the
airplane. A rudder operates by redirecting the fluid past the hull (watercraft) or
fuselage, thus imparting a turning or yawing motion to the craft. In basic form,
a rudder is a flat plane or sheet of material attached with hinges to the craft's
stern, tail, or after end. Often rudders are shaped so as to minimize
hydrodynamic or aerodynamic drag. On simple watercraft, a tiller—essentially,
a stick or pole acting as a lever arm—may be attached to the top of the rudder
to allow it to be turned by a helmsman. In larger vessels, cables, pushrods, or
hydraulics may be used to link rudders to steering wheels. In typical aircraft,
the rudder is operated by spur gear connected to the shaft of the pneumatic
Project pictures
 Breakdown of project expenditure
s.no MATERIAL SUPPLIER NAME COST

1 BODY OF THE MODEL INNOVATIVE 3000

FRABICATORS

2 PNEUMATIC CYLINDER INNOVATIVE 2000

FABRICATORS

3 FLOW CONTROL VALVE PRASANTH 500

HYDRAULICS

4 CONNECTORS AND HOSES PRASANTH 100

HYDRAULICS

5 GEAR WHEEL AND SHAFT INNOVATIVE 1500

FRABICATORS

6 DC AIR COMPRESSOR AMAZON 3000

7 BATTERY AMAZON 1500

8 RUDDER INNOVATIVE 800

FRABICATORS
 CONCLUSION

The project is about operation of steering gear by using

compressed air instead of hydraulic oil like the most
steering gears.
The arrangements are made in a such a way that the
compressed air from a dc compressor is utilized to
change the rudder position according to requirement
and in actual ships we can have air bottle arrangement
so the compressed air can be stored and used during
emergency situations to steer the ship without
depending on the ship,s power supply and there will be
much usage of oil eliminating the risk of oil leakage
from steering gear.