AUTOMATIC PNEUMATIC BRAKE

PROJECT REPORT 2023-2024

Submitted by:
(Team name)

COLLEGE LOGO

Guided by:

Submitted in partial fulfillment of the

requirement for the

Award of Diploma in

-----------------------------------------

By the State Board of Technical Education

Government of

Tamilnadu, Chennai.
 Department:

College name:

Place:

COLLEGE NAME

COIMBATORE

DEPARTMENT

PROJECT REPORT-202-2024

This Report is certified to be the Bonafide work done by

Selvan/Selvi ---------------- Reg.No.------------ of VI
Semester class of this college.

Guide Head of the Department

Submitter for the Practical Examinations of the board of

Examinations,State Board of Technical Education,Chennai,
TamilNadu.On --------------(date) held at the ------------
(college name),Coimbatore
Internal Examiner External Examiner

ACKNOWLEDGEMENT

At this pleasing movement of having successfully

completed our project, we wish to convey our sincere thanks
and gratitude to the management of our college and our
beloved chairman------------------------.who provided all the
facilities to us.

We would like to express our sincere thanks to our

principal ------------------for forwarding us to do our project and
offering adequate duration in completing our project.

We are also grateful to the Head of Department

prof…………., for her/him constructive suggestions
&encouragement during our project.

With deep sense of gratitude, we extend our earnest

&sincere thanks to our guide --------------------, Department of
Mechanical for her/him kind guidance and encouragement
during this project we also express our indebt thanks to our
TEACHING staff of MECHANICAL ENGINEERING DEPARTMENT,
---------- (college Name).

AUTOMATIC PNEUMATIC BRAKE

 CONTENTS

CHAPTER NO TITLE

SYNOPSIS
LIST OF FIGURES
NOMENCLATURE
1 Introduction
2 Literature review
3 Description of equipments
3.1 Pneumatic cylinder
3.2 Valves
3.3 Ultrasonic sensor
3.4 Brake
3.5 Wheel
3.6 Motor
3.7 Spur gear
4 Design and drawing
4.1 Design calculation
4.2 Block diagram
4.3 Overall diagram
5 Working principle
6 Merits and demerits
7 Applications
8 List of materials
9 Cost Estimation
10 Conclusion
BIBLIOGRAPHY

PHOTOGRAPHY
 LIST OF FIGURES

Figure
Number Title

1 Overall Diagram
 NOMENCLATURE

 A =Area of cylinder(m2 )

 D=Diameter of Piston (m)

 F =Force exerted on the piston (N)

 H=Height (m)

 L=Length(m)

 P=Pressure (N/m2)

 V=Volume (m3)
 SYNOSPIS

The Objective of this project is to, stop the vehicle in which the Break

control is fixed and to control the vehicle, if the distance between the

vehicles is less than the desired value. In Roads, where heavy Traffic

prevails, the possibilities of occurrence of accidents are large. Hence in order

to prevent accidents, we have designed this project, which automatically

stops the vehicle in which the Break control is fixed and control the vehicle,

if the distance between the vehicles is less than the desired value.
 CHAPTER I

INTRODUCTION

Now-a-days safety is become important aspects of automobile

industries. And automation is the key which keep the safety at our fingers. In

other words, an unskilled or less exampled can handle the automobile

vehicle with greater with safety. Various accidents happen with the

automobile vehicles which cause serious injury, and inefficient braking is

most probable reason. It is incontestable, statistically proved fact, that year

on year incidents involving a reversing vehicle account for between 20-30%

of all reported work related serious injuries or fatalities. While parking or

taking reverse turn, driver unable to see what is behind the vehicle and

obviously up to what distance, eventually vehicle strike with the obstacle

behind. Presently, cars have the alarm system where when the car gets too

close to an object an alarm is triggered which warns the driver about an

object close by. But this feature has produced lot of problems and is prone to

human error. We have enhanced the facility by using the same system but

we have altered it so that the car brakes automatically when an obstacle is

close by. This project introduces a control systems based on electronically

controlled automotive braking system is called “Intelligent Braking

System”. A Sensor Operated Pneumatic Brake consists of Ultrasonic

transmitter and Receiver circuit, Control Unit, Pneumatic breaking system.

The ultrasonic sensor is used to detect the obstacle. There is any obstacle in

the path, the ultrasonic sensor senses the obstacle and giving the control

signal to the breaking system. The pneumatic breaking system is used to

brake the system. So basically here the car brakes on its own by determining

the distance from the object.

Car safety is the avoidance of automobile accidents or the

minimization of Harmful effect of accidents in particular as pertaining

to human life and health. Special safety features have been built into

cars for years.

Automation can be achieved through computers, hydraulics,

pneumatics, robotics etc., of these sources, pneumatics form an

attractive medium for low cost automation.

Automation plays an important role in automobile. Now days, all

most the entire automobile vehicle is being atomized in order to

product the human being.

The automobile vehicle is being atomized for the following reasons.

 To achieve high safety

 To increased the efficiency of the vehicle

 To reduce the vehicle accident

 To reduce the fatigue of workers

 To high responsibility

 Less Maintenance cost

 CHAPTER II

LITERATURE SURVEY

A brake is a device by means of which artificial frictional

resistance is applied to a moving machine member,in order to retard

or stop the motion of a machine. In the process of performing this

function, the brake absorbs either kinetic energy of the moving

member or potential energy given up by objects being lowered by

hoists, elevators etc. the energy absorbed by brakes is dissipated in

the form Of heat. This heat is dissipated in the surrounding air (or

water which is circulated through the passages in the brake drum. So

that excessive heating of the brake lining does not take place.

 The unit pressure between the braking surfaces

 The coefficient of friction between the braking surfaces

 The peripheral velocity of the brake drum

 The project area of the friction surfaces, and

 The ability of the brake to dissipate heat equivalent to the

energy being absorbed

The energy absorbed by a brake depends upon the type of

motion of the moving body. The motion of a body may be either pure
translation or pure rotation or a combination of both translation and

rotaion. The energy corresponding to these motions is kinetic energy.

The brakes are one of the most important control components

of vehicle. They are required to stop the vehicle within the smallest

possible distance and this is done by converting the kinetic energy of

the vehicle into the heat energy which is dissipated into the

atmosphere. The brake must be strong enough to stop the vehicle

within a minimum distance in an emergency. But this should also be

consistent with safety. The driver must have proper control over the

vehicle during emergency braking and the vehicle must not skid. The

brakes must have good effectiveness should not decrease with

constant prolonged application while descending be very efficient.

This type of brakes, through not very popular, as service

brakes, has been commonly used on trailers. One such example is

Warner electric brake.

The current from the battery is utilized to energize an

electromagnet within the brake drum, which in turn actuates the

mechanism to expand the brake shoes. When current stops passing,

the cam brake shoes are returned to the release position by retractor
springs. The severity of braking is controlled by means of a rheostat,

which is operated by the driver through the foot pedal.

As an alternative to the foot-operated rheostat, hydraulic

pressure has also been used to apply electric brakes. As pedal is

pressed more, hydraulic pressure actuates the rheostat to increase

the current to the electromagnet. Still another method uses an inertia

weight to uncover a light. As the brakes are applied for the main

vehicle, it slows down due to which the weight or pendulum in the

trailer brake control device moves forward, exposing a light-sensitive

diode to more of the light beam. This increases the current to the

electromagnet in the trailer brake, there by applying these brakes.

The word ‘pneuma’ comes from Greek and means 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 that of the air at

intake conditions namely at atmosphere pressure and normal

ambient temperature.

The compressibility of the air was first investigated by Robot

Boyle in 1962 and that found that the product of pressure and

volumes of particular quantity of gas.

 The usual written as

PV =C (or) PiVi =P2V2

In this equation the pressure is the absolute pressured which

for free is about 14.7Psi 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.

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 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

Economic and simplicity the latter reducing maintenance to a low

level. It can have out standing advantages in terms of safety.

 Pneumatic systems use pressurized gases to transmit and

control power. Pneumatic systems typically use air as the fluid

medium because air is safe, low cost and readily available.

THE ADVANTAGES OF PNEUMATICS

1. Air used in pneumatic systems can be directly exhausted back

In to the surrounding environment and hence the need of special

reservoirs and no-leak system designs are eliminated.

2. Pneumatic systems are simple and economical

3. Control of pneumatic systems is easier

THE DISADVANTAGES OF PNEUMATICS

1. Pneumatic systems exhibit spongy characteristics due to

compressibility of air.

2. Pneumatic pressures are quite low due to compressor design

limitations(less that 250 psi).

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 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 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 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.

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 500m3/min.In single stage compressor, the air

pressure may be of 6 bar machines discharge of pressure is up to

15bars.Discharge pressure in the range of 250bars can be obtained

with high pressure reciprocating compressors that of three & four

stages. Single stage and 1200 stage models are particularly suitable

For applications, with preference going to the two stage design as

soon as the discharge pressure exceeds 6 bars, because it in

capable of matching the performance of single stage machine at

lower costs per driving powers in the range.

 CHAPTER III

DESCRIPTION OF EQUIPMENT

3.1PNEUMATIC CYLINDER

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

energy of compressed air i.e.penuamtic power is converted into

mechanical Output power, by reducing the pressure of the air to that

of the atmosphere.

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 stroke single

action cylinder requires only about half the air volume consumed by a

double acting for one operating cycle.

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 stroke. 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 stroke 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 strokes in the other direction at full

force and velocity.

3.2 VALVES

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.

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

a varnish that is not affected by solvents, moisture, cutting oil or often

fluids. Coils are rated in various voltages such as 115 volts AC,

230volts AC, 460volts Ac, 575 Volts AC.6Volts DC, 12Volts DC, 24

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

Frequencies as 50Hz to 60Hz.

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 coils attract 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 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.

The solenoid valve has 5 openings. These ensure easy

exhausting of 5/2Valve.the spool of the 5/2 valve slide inside the main

bore according to spool position: the ports get connected and

disconnected.

The working principle is as follows.

Position-1

When the spool is actuated towards outer direction port ‘P’ gets

Connected to ‘B’ and ‘S’ remains closed while ‘A’ gets connected to

‘R’.

Position-2

When the spool is pushed in the inner direction port ‘P’ and ‘A’

Gets connected to each other and ‘B’ to ‘S’ while port ‘R’remains

closed.
3.2.2 FLOW CONTROL VALVE

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

the speed of actuator. The flow 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.
3.2.3 PRESSURE CONTROL VALVE

The main function of the pressure control valve is to limit (or)

Control the pressure required in a pneumatic circuit.

Depending upon the method of controlling they are classified as

1. Pressure relief valve

2. Pressure reducing valve

3.3. ULTRASONIC SENSOR

The ultrasonic wave is spread in the air and hit the nearest

object and reflected from the object which is received by the

ultrasonic receiver. The received wave is given to amplifier in order to

amplify the received weak signal. After the amplification the amplified

wave is given to zero adjustment amplifier because the amplified

wave is in the range of above 6v level. Then the output is given to

comparator in which the wave signal is converted into corresponding

square wave signal. Then the square wave signal is given to input of

the microcontroller. Now the microcontroller compares the time

between the transmitted signal and received signal and generates the

corresponding pulse output which is equal to distance of the object.

3.4 BRAKE

The brakes are one of the most important control components

of vehicle. They are required to stop the vehicle within the smallest

possible distance and this is done by converting the kinetic energy of

the vehicle into the heat energy which is dissipated into the

atmosphere. The brake must be strong enough to stop the vehicle

within a minimum distance in an emergency. But this should also be

consistent with safety. The driver must have proper control over the

vehicle during emergency braking and the vehicle must not skid. The

brakes must have good effectiveness should not decrease with

constant prolonged application while descending be very efficient.

This type of brakes, through not very popular, as service

brakes, has been commonly used on trailers. One such example is

Warner electric brake.

The current from the battery is utilized to energize an

electromagnet within the brake drum, which in turn actuates the

mechanism to expand the brake shoes. When current stops, the cam

brake shoes are returned to the release position by retractor springs.

The severity of braking is controlled by means of a rheostat, which is

operated by the driver through the foot pedal.

 As an alternative to the foot-operated rheostat, hydraulic

pressure has also been used to apply electric brakes. As pedal is

pressed more, hydraulic pressure actuates the rheostat to increase

the current to the electromagnet. Still another method uses an inertia

weight to uncover a light. As the brakes are applied for the main

vehicle, it slows down due to which the weight or pendulum in the

trailer brake control device moves forward, exposing a light-sensitive

diode to more of the light beam. This increases the current to the

electromagnet in the trailer brake, there by applying these brakes.

3.6. WHEEL:

A wheel is a circular device that is capable of rotating on its

axis, facilitating movement or transportation or performing labour in

machines. A wheel together with an axle overcomes friction by

facilitating motion by rolling. In order for wheels to rotate a moment

needs to be applied to the wheel about its axis, either by way of

gravity or by application of another external force. Common examples

are found in transport applications. More generally the term is also

used for other circular objects that rotate or turn, such as a Ship's

wheel and flywheel. The wheel most likely originated in ancient

 The wheel is a device that enables efficient movement of an

object across a surface where there is a force pressing the object to

the surface. Common examples are a cart drawn by a horse, and the

rollers on an aircraft flap mechanism.

The wheel is not a machine, and should not be confused with

the wheel and axle, one of the simple machines. A driven wheel is a

special case that is a wheel and axle. Wheels are used in conjunction

with axles, either the wheel turns on the axle or the axle turns in the

object body. The mechanics are the same in either case. The normal

force at the sliding interface is the same. The sliding distance is

reduced for a given distance of travel. The coefficient of friction at the

interface is usually lower.

3.7. DC MOTOR

Permanent Magnet DC motors are useful in a range of

applications, from battery powered devices like wheelchairs and

power tools, to conveyors and door openers, welding equipment, X-

ray and tomographic systems, and pumping equipment, to name a

few.
 They are frequently the best solution to motion control and

power transmission applications where compact size, wide operating

speed range, ability to adapt to a range of power sources or the

safety considerations of low voltage are important. Their ability to

produce high torque at low speed make them suitable substitutes for

gearmotors in many applications. Because of their linear speed-

torque curve, they particularly suit adjustable speed and servo control

applications where the motor will operate at less than 5000 rpm.

Inside these motors, permanent magnets bonded to a flux-

return ring replace the stator field windings found in shunt motors. A
wound armature and mechanical brush commutation system

complete the motor.

The permanent magnets supply the surrounding field flux,

eliminating the need for external field current. This design yields a

smaller, lighter, and energy efficient motor.

3.8. SPUR GEAR

Spur gears are the simplest and most common type of gear.

Their general form is a cylinder or disk. The teeth project radially, and

with these straight-cut gears, the leading edges of the teeth are

aligned parallel to the axis of rotation. These gears can only mesh

correctly if they are fitted to parallel axles. The torque ratio can be

determined by considering the force that a tooth of one gear exerts

on a tooth of the other gear. Consider two teeth in contact at a point

on the line joining the shaft axes of the two gears. The force will have

both a radial and a circumferential component. Gears are a very

useful simple machine. The torque ratio can be determined by

considering the force that a tooth of one gear exerts on a tooth of the

other gear. Consider two teeth in contact at a point on the line joining

the shaft axes of the two gears.

 A gear is component within a transmission device. Transmit

rotational force to another gear or device. A gear is different from a

pulley in that a gear is a round wheel. Mesh with other gear teeth,

allowing force to be fully transferred without slippage. Depending on

their construction and arrangement, geared devices can transmit

forces at different speeds, torques, or in a different direction, from the

power source. Gears are a very useful simple machine. The most

common situation is for a gear to mesh with another gear, but a gear

can mesh with any device having compatible teeth, such as linear

moving racks.
 CHAPTER IV

DESIGN OF EQUIPMENT AND DRAWING

4.1 DESIGN CALCULATION

CALCULATION
DESIGN CALCULATION FOR PNEUMATIC CYLINDER

(32 x 100)

Mini pressure applied in the cylinder (P) = 2x105N/m2 (2 bar)

Diameter of the cylinder (D) = 32 mm

Diameter of the piston rod (d) = 17 mm

Stroke length = 100 mm

Area of cylinder (A) = (3.14/4*(D2)

= (0.785x.0322)

A= 8.0384 x 10-4 m2

Force during forward stroke,

F = {π/4x D^2 x P}

F = (2 x 105 N /m2) (3.14/4*(0.0322)

F = 160.68 N

1kg = 9.81 N

Load capacity during forward stroke W= F / a

 W = 160.68 / 9.81

W= 16.37 KG

Force during return stroke,

F = {π/4x (D^2 – d^2) x P}

F = {π/4x (0.032^2 – 0.017^2) x 2x105}

F = 115.45 N

Load capacity during return stroke W= F / a

W= 115.45 / 9.81

W= 11.76 KG

For all practical purposes, design your system 25% over and above

your theoretical calculations.

 Graph for distingution between force Vs air pressure

THEORETICAL AIR CONSUMPTION CALCULATIONS:

During Forward stroke,

Air consumption = {π/4x (D^2) x L}

Air consumption = {π/4x (0.032^2) x 0.1}

Air consumption = 8.042 x 10-5 m3

1 m3 = 1000 liter

Air consumption = 0.0804 liter

Boyles Law, P1V1 = P2V2

V2 = P1V1/ P2

V2 = (2+1) (0.0804)/ 1

V2 =0.2412 liter /stroke

During return stroke,

Air consumption = {π/4x (D^2- d^2) x L}

Air consumption = {π/4x (0.032^2 – 0.017^2) x0.1}

Air consumption = 5.77 x 10-5 m3 = 0.0577 liter

Boyles Law, P1V1 = P2V2

V2 = P1V1/ P2

V2 = (2+1) (0.0577)/ 1

V2 = 0.1731 liter /stroke

Theoretical air consumption per cycle = (Air consumption during

forward stroke + Air consumption during return stroke)

Theoretical Air consumption per cycle =0.2412 + 0.1731= 0.4143

liter/ cycle
In actual practice, approximately 2/3 of this flow is obtained. Assume

75% of line pressure is actually working on the load. The remaining

25% is consumed by flow losses in the valve and connecting lines.

CALCULATING LOAD BEARING CAPACITY OF PISTON ROD

In our case the pressure is applied by on one face of the piston

while the other cross section of the piston faces the fixed wall. This

means that the failure or breakage of piston rod will occur only due to

excessive compressive stress developed in the piston rod.

As we know that the maximum limit of compressive stress that

a stainless steel specimen can bear is 310 MPa.

Since the diameter of the piston rod is 17 mm therefore we can

lastly calculate the amount of maximum load which can be beard by

the piston.

σ =F/A

Where.,

R = radius of the piston rod,

σ = stress,

A = area of the piston head.

But, A = πR2
 Area = π (8.5)2

A = 226.98 mm2

stress (σ) = 310 N/mm2

Force = stress x Area

= 310 x 226.98

= 70363.8 N

We know,

1 Kg force = 9.81 N

Force (F) = 70363.8/9.81

F = 7172.66 Kg

Also we know,

1 Tone = 1000 kg.

F = 7 Tones

This means that 7 tones is that 7 tones is the last limit of our piston

rod. But our aim is to design the pneumatic cylinder which can easily

with stand with 0.5 to 1 tones.

 Diagram for Sectional view of cylinder

SELECTION OF STANDARD PNEUMATIC CYLINDER

DESIGN PARAMETER

Required load to be lifted = 5 kg

Factor of safety for pneumatic cylinder = 3 (Constant Load)

Supply Pressure = 2 bar

Solution:

Load to be lifted = 5 kg =5 Kg x 9.81 m/s2 = 49.05 N

Design load = Load to be lifted x Factor of safety

Design load = 49.05 x 3 = 147.15 N

{ D^2 } = F/( π/4 x P)

{D^2 } = 147.15 /( π/4 x 2 x 105)

D = 0.03048 m= 30.48 mm

STANDARD PNEUMATIC
CYLINDER SIZE
DIAMETER STROKE LENTH
100 100
125 100
15 100
16 100
16 50
20 150
32 100
32 150
32 25
32 300
 32 50
32 750
40 100
50 100

From table,

32 diameter cylinder is enough for particular design load and

length piston rod varies depends upon application.

SELECTION OF AIR CYLINDER SPEED

Estimating cylinder speed is extremely difficult because of the

flow losses within the system in piping, fittings, and porting through

the valves which are in the air path. Flow losses cause a loss in

pressure which directly effect the force output. To be able to

determine the maximum speed of the cylinder, the sum of all flow

losses, pressure required for the force output and the available inlet

pressure must be known. Circuit losses cannot be determined or

calculated accurately.
Speed of piston can be referred from above chart for corresponding

fittings. In 32 x100 cylinder, 1/8 inch normal or speed control fitting

can be used
 .

3D drawing for normal fitting

SELECTION OF DIRECTION CONTROL VALVE
In general, Double Acting Cylinder can be operated by using Valve

that choices to supply them are to use two 3/2 valves, a single 4/2

valve, a single 5/2 valve, or a single 5/3 air valve.

Since the purchase of one air valve will cost less than two valves of

comparable size, circuit designers will opt for a single 5/2 or 4/2

solenoid valve to operate the double acting air actuator rather than

two 3/2 valves. 5/2 has two exhaust ports but 4/2 has only one

exhaust port.
The additional exhaust port provides significant benefit to the system

design. That's why, in selecting a valve for a double acting actuator, I

would always opt for a 5/2 version over a 4/2.

CALCULATION FOR FORCE REQUIRE TO MOVE LOAD AT

ANGLE

FANGLE = F x SIN (deg)

Force Require, FANGLE = F x SIN (deg)
F = load in Newton = 10 N (assume)
Load at Angle = 45o

FANGLE = F x SIN (deg)

FANGLE = 10 x SIN (45o)
FANGLE = 7.07N
 DC MOTOR CALCULATION

SPECIFICATION:

Speed N = 30 RPM
Voltage V = 12 Volt

Current I = 0.3 A (loading condition)

Current I = 0.06 A (No Load Condition)

Power P =V x I=12x0.3 = 3.6 WATT

P= 0.0048 HP

Motor Efficiency = 36%

Motor shaft diameter = 6 mm

FORMULEA

Good science project does not stop with building a motor. It is very

important to measure different electrical and mechanical parameters

of your motor and calculate unknown values using the following

helpful formulas.

This formula could be used in many cases. You may calculate the

resistance of your motor by measuring the consumed current and

applied voltage. For any given resistance (in the motors it is basically
the resistance of the coil) this formula explains that the current can be

controlled by applied voltage.

Electrical power of the motor is defined by the following formula:

Pin = I * V

Where,

Pin – input power, measured in watts (W)

I – current, measured in amperes (A)

V – applied voltage, measured in volts (V)

Motors supposed to do some work and two important values define

how powerful the motor is. It is motor speed and torque – the turning

force of the motor. Output mechanical power of the motor could be

calculated by using the following formula

Pout = Τ * ω

Where,

Pout – output power, measured in watts (W)

τ – torque, measured in Newton meters (Nm)

ω – angular speed, measured in radians per second (rad/s).

Calculate angular speed if you know rotational speed of the motor in

rpm:

ω = N * 2π / 60

Where,

ω – Angular speed, measured in radians per second (rad/s);

rpm – rotational speed in revolutions per minute;

π – Mathematical constant pi (3.14).

60 – Number of seconds in a minute.

Efficiency of the motor is calculated as mechanical output power

divided by electrical input power:

E = Pout / Pin

Therefore

Pout = Pin * E

After substitution we get

 Τ*ω=I*V*E

Τ * N * 2π / 60 = I * V * E

Connect the motor to the load. Using the motor from generator kit is

the best way to do it. Why do you need to connect the motor to the

load? Well, if there is no load – there is no torque. Measure current,

voltage and rpm. Now you can calculate the torque for this load at

this speed assuming that you know efficiency of the motor. Motor

torque changes with the speed. At no load you have maximum speed

and zero torque. Load adds mechanical resistance. The motor starts

to consume more current to overcome this resistance and the speed

decreases. If you increase the load at some point motor stops (this is

called stall). When it occurs the torque is at maximum and it is called

stall torque. While it is hard to measure stall torque without special

tools you can find this value by plotting speed-torque graph. You

need to take at least two measurements with different loads to find

the stall torque.

TORQUE OF THE MOTOR:

And the formula for calculating torque will be

Τ = (I * V * E *60) / (N * 2π)

= (0.3x12x0.36x60)/30x2π

Torque = 0.412 Nm

Torque (T) = 4.2kgcm

24 TEETH SPUR GEAR

Diameter of gear = Ø32mm

No of teeth =24 no

Thickness of the gear =10.5 mm

MODULE. m:
This is the standard term used in S.I.units. It can be defined as the
length on the pitch circle diameter per tooth. It is the reverse of the
diameter pitch.
m = D/T
m = 32/24
m = 1.33mm

ADDENDUM: (a)
The radial distance between the pitch circle and the tip circle is
known as Addendum.
a=1m
a = 1 x 1.33
a = 1.33 mm
DEDENDUM:
The radial distance between the pitch circle and the root circle is
known as Dedendum (d).
d=1.25m
d = 1.25 x 1.33
d = 1.66 mm

DIAMETRAL PITCH (Pd):

It is the ratio of the number of teeth per unit pitch diameter. This
Is a mostly used in F.P.S. system.

Pd= (T+2)/D
Pd = 26/32
Pd = 0.8125 mm

CIRCULAR PITCH (Pc):

The distance between the corresponding sides of two adjacent of a

gear measured on the pitch circle is known as circular pitch.
Pc = / Pd
Pc = / 0.8125
Pc = 3.86 mm
48 TEETH SPUR GEAR

Diameter of gear = Ø62mm

No of teeth =48 no

Thickness of the gear =10.5mm

MODULE. m:
This is the standard term used in S.I.units. It can be defined as the
length on the pitch circle diameter per tooth. It is the reverse of the
diameter pitch.

m = D/T
m = 62/48
m = 1.29 mm

ADDENDUM: (a)
The radial distance between the pitch circle and the tip circle is
known as Addendum.
a=1m
a = 1 x 1.29
a = 1.29 mm
DEDENDUM:
The radial distance between the pitch circle and the root circle is
known as Dedendum (d).
d=1.25m
d = 1.25 x 1.29
d = 1.6125 mm

DIAMETRAL PITCH (Pd):

It is the ratio of the number of teeth per unit pitch diameter. This
Is a mostly used in F.P.S. system.

Pd= (T+2)/D
Pd = 50/62
Pd = 0.806 mm
CIRCULAR PITCH (Pc):

The distance between the corresponding sides of two adjacent of a

gear measured on the pitch circle is known as circular pitch.
Pc = / Pd
Pc = / 0.806
Pc = 3.89 mm
DRAWING
4.2 BLOCK DIAGRAM
4.3 DRAWING FOR SENSOR OPERATED AUTOMATIC REVERSE
BRAKING SYSTEM
 CHAPTER V

WORKING PRINCIPLE

In this project we are using ultrasonic sensor for detecting

the objects or vehicles in front of our vehicle. It also measures the

distance of the vehicle in front of ours. It consists of ultrasonic

transmitter and receiver. The transmitter always transmitting the

waves, the receiver receives the reflected waves and converts it in to

digital pulse. The ultrasonic sensor sends the output to the controller.

The pulse time will vary depends on the closeness between the

sensor and the object. Using this pulse timing the controller measures

the distance. When the distance becomes low, the controller will

switch on the relay for applying braking. Here the pneumatic cylinder

braking mechanism is used for applying brake in the wheel.

Pneumatic cylinders are mechanical devices which produce force,

often in combination with movement, and are powered by

compressed gas (typically air).To perform their function, pneumatic

cylinders impart a force by converting the potential energy of

compressed gas into kinetic energy. This is achieved by the

compressed gas being able to expand, without external energy input,

which itself occurs due to the pressure gradient established by the

compressed gas being at a greater pressure than the atmospheric

pressure. This air expansion forces a piston to move in the desired

direction. Once the proximity sensor sense high speed, controller will

switch on the relay for applying braking and reverse gear detection

and switches on the alarm also the pneumatic cylinder is actuated for

apply the brake. The vehicle is run by motorized spur gear

arrangement.
 CHAPTER VI

MERITS AND DEMERITS

MERITS

 Automatically operated

 Easy implementation

 Reliable

 Good efficient

DEMERITS

 Compressor is required for operating pneumatic cylinder

 CHAPTER VII

APPLICATION

 Applicable in all four wheeler and heavy vehicles.

 CHAPTER VIII

LIST OF MATERIALS

FACTORS DETERMINING THE CHOICE OF MATERIALS

The various factors which determine the choice of material are

discussed below.

1. Properties:

The material selected must posses the necessary properties for

the proposed application. The various requirements to be satisfied

can be weight, surface finish, rigidity, ability to withstand

environmental attack from chemicals, service life, reliability etc.

The following four types of principle properties of materials

decisively affect their selection

a. Physical

b. Mechanical

c. From manufacturing point of view

d. Chemical
 The various physical properties concerned are melting point,

thermal Conductivity, specific heat, coefficient of thermal expansion,

specific gravity, electrical conductivity, magnetic purposes etc.

The various Mechanical properties Concerned are strength in

tensile, Compressive shear, bending, torsional and buckling load,

fatigue resistance, impact resistance, eleastic limit, endurance limit,

and modulus of elasticity, hardness, wear resistance and sliding

properties.

The various properties concerned from the manufacturing point

of view are,

 Cast ability

 Weld ability

 Surface properties

 Shrinkage

 Deep drawing etc.

2. Manufacturing case:

Sometimes the demand for lowest possible manufacturing cost

or surface qualities obtainable by the application of suitable coating

substances may demand the use of special materials.

3. Quality Required:

This generally affects the manufacturing process and ultimately

the material. For example, it would never be desirable to go casting of

a less number of components which can be fabricated much more

economically by welding or hand forging the steel.

4. Availability of Material:

Some materials may be scarce or in short supply, it then

becomes obligatory for the designer to use some other material which

though may not be a perfect substitute for the material designed. The

delivery of materials and the delivery date of product should also be

kept in mind.

5. Space consideration:

Sometimes high strength materials have to be selected because the

forces involved are high and space limitations are there.

6. Cost:

As in any other problem, in selection of material the cost of

material plays an important part and should not be ignored.

 Some times factors like scrap utilization, appearance, and non-

maintenance of the designed part are involved in the selection of

proper materials.

CHAPTER IX

COST ESTIMATION

1. LABOUR COST

Lathe, drilling, welding, power hacksaw, gas cutting cost

2. OVERHEAD CHARGES

The overhead charges are arrived by” manufacturing cost”

Manufacturing Cost =Material Cost + Labour Cost

Overhead Charges =20%of the manufacturing cost

3. TOTAL COST

Total cost = Material Cost +Labour Cost +Overhead Charges

Total cost for this project =

 CHAPTER X

CONCLUSION

The project carried out by us will make an impressing mark in

the field of automobile. It is very useful to avoid the accident due to

carelessness of driver. Pneumatic is one of quick functioning device

that provide the instant reaction from controller unit

This project has also reduced the cost involved in the concern.

The project has been designed to perform the required task taking

minimum time.
 BIBLIOGRAPHY

1. Design data book -P.S.G.Tech.

2. Pneumatic handbook -R.H.warrning

3. Machine tool design handbook –Central machine tool

Institute, Bangalore.

4. Strength of Materials -R.S.Kurmi

5. Manufacturing Technology -M.Haslehurst.

6. Design of machine elements- R.s.Kurumi

PHOTOGRAPHY