DOI:10.23883/IJRTER.2018.4157.31AEY 502

HYBRIDIZATION OF PNEUMATICALLY OPERATED AIR

ENGINE WITH AUTOMATIC REFUELLING

CONTENTS

CHAPTER NO. TITLE PAGE NO.

List of figures 3

Synopsis 4

1 Introduction 6

2 Literature review 7

3 Description of equipment’s

3.1 Compressor

3.2 Solenoid valve

3.3 Pneumatic

12

4 Design and drawing

4.2 General Machine Components

19

5 Working principle 23

6 Merits & demerits 24

7 Applications 25

8 List of materials 26

9 Cost Estimation ( BOM ) 29

10 Conclusion 30

Bibliography 31

Photography 32

LIST OF FIGURES

Figure

Number

Title

Page no

3.1.2 5/2 Solenoid valve 14

4.1.1 Air Compressor 19

4.1.2 Solenoid valve cut off 20

4.1.3 Solenoid Valve 21

5.1 Overall Schematic 22

SYNOPSIS

This air engine is the new innovative concept to run the bicycle by using the compressed air system.

Begins with an introduction to pneumatic it’s various applications and units and briefly explains a

few devices capable of utilizing air effectively and their relative merits. The pneumatic operated of

air engine is equipment and it is very useful for drive the vehicle. It is operated by pneumatic system.

Air is the working substance of our machine. This system gives smooth operation and smooth

vehicle movement.

International Journal of Recent Trends in Engineering & Research (IJRTER) Volume 04, Issue 03; March- 2018 [ISSN: 2455-1457]

@IJRTER-2018, All Rights Reserved 503

Pneumatics is an aspect of physics and engineering that is concerned with using the energy in

compressed gas to make something move or work. The origins of pneumatics trace back to the first

century when the Greek mathematician Hero of Alexandria created mechanical systems powered by

wind and steam and documented his processes. Today, pneumatics plays an important role in

manufacturing and mechatronics.

With pneumatics, valves control the flow of energy from pressurized gas, which is often

simply compressed air. The device that converts energy from the pressurized gas into motion is

called a pneumatic actuator. Pneumatic actuators are often powered by electric compressors and are

capable of producing either linear or rotary motion. A nail gun is an example of a linear pneumatic

actuator. When the user pulls the nail gun's trigger, a valve opens and compressed air is released with

enough force to drive the nail into a solid surface. In manufacturing, pneumatic technology and

automated solenoid valves can be used in an assembly line to move, process and package product.

In our project we use pneumatic devices such as solenoid valves, pneumatic single and double

acting cylinders and a compressed air tank to act as a reservoir of air through which the pneumatic

components can operate. We have also attached a compressor which serves the purpose of

replenishing the air in the tank simultaneously as it gets consumed due to operation of pneumatic

components.

The biggest advantage we have over this alternative is that the fuel used in this pneumatically

operated vehicle is compressed air. There are no emissions resulting from the operation of the

engine. The power and torque of the engine can be varied as per requirement by increasing the

number of pneumatic cylinders. The engine operates by a pneumatic solenoid valve that receives air

from the tank. The two pneumatic double acting cylinders convey from the two ends of a solenoid

valve.

The solenoid valve’s opening and closing is controlled by means of a programmable logic

controller (PLC).

The PLC includes an ON OFF program which establishes an alternative control of opening and

closing of each outlet of a solenoid valve. This causes the pneumatic cylinders to operate

alternatively i.e. one piston is in its top dead center and the other cylinder is in its bottom dead

center.

The attachment on the piston drags the chain linking between the front axle and the rear axle.

This is the conversion of reciprocating motion into rotary and translation motion. This in turn causes

the vehicle to propel forward.

I. INTRODUCTION

Vehicles, derived from the Latin word, vehiculum, are non-living means of transport. Most often they

are manufactured (e.g. bicycles, cars, motorcycles, trains, ships, boats, and aircraft), although some

other means of transport which are not made by humans also may be called vehicles; examples

include icebergs and floating tree trunks.

Vehicles may be propelled or pulled by animals, for instance, a chariot, a stagecoach, a mule-drawn

barge, or an ox-cart. However, animals on their own, though used as a means of transport, are not

called vehicles, but rather beasts of burden or draft animals. This distinction includes humans

carrying another human, for example a child or a disabled person.

A rickshaw is a vehicle that may carry a human and be powered by a human, but it is the mechanical

form or cart that is powered by the human that is labeled as the vehicle. For some human-powered

vehicles the human providing the power is labeled as a driver.

International Journal of Recent Trends in Engineering & Research (IJRTER) Volume 04, Issue 03; March- 2018 [ISSN: 2455-1457]

@IJRTER-2018, All Rights Reserved 504

Vehicles that do not travel on land often are called craft, such as watercraft, sailcraft, aircraft,

hovercraft, and spacecraft Land vehicles are classified broadly by what is used to apply steering and

drive forces against the ground: wheeled, tracked, railed, or skied.

II. LITERATURE SURVEY

HISTORY OF THE AUTOMOBILE

Although Nicolas-Joseph Cugnot is often credited with building the first self-propelled mechanical

vehicle or automobile in about 1769 by adapting an existing horse-drawn vehicle, this claim is

disputed by some, who doubt Cugnot's three-wheeler ever ran or was stable. Others claim Ferdinand

Verbiest, a member of a Jesuit mission in China, built the first steam-powered vehicle around 1672

which was of small scale and designed as a toy for the Chinese Emperor that was unable to carry a

driver or a passenger, but quite possibly, was the first working steam-powered vehicle ('auto-

mobile'). What is not in doubt is that Richard Trevithick built and demonstrated his Puffing Devil

road locomotive in 1801, believed by many to be the first demonstration of a steam-powered road

vehicle although it was unable to maintain sufficient steam pressure for long periods, and would have

been of little practical use.

In Russia, in the 1780s, Ivan Kulibin developed a human-pedalled, three-wheeled carriage with

modern features such as a flywheel, brake, gear box, and bearings; however, it was not developed

further. François Isaac de Rivaz, a Swiss inventor, designed the first internal combustion engine, in 1806,

which was fueled by a mixture of hydrogen and oxygen and used it to develop the world's first

vehicle, albeit rudimentary, to be powered by such an engine. The design was not very successful, as

was the case with others such as Samuel Brown, Samuel Morey, and Etienne Lenoir with his

hippomobile, who each produced vehicles (usually adapted carriages or carts) powered by clumsy

internal combustion engines.

In November 1881 French inventor Gustave Trouvé demonstrated a working three-wheeled

automobile that was powered by electricity. This was at the International Exhibition of Electricity in

Paris.

Although several other German engineers (including Gottlieb Daimler, Wilhelm Maybach, and

Siegfried Marcus) were working on the problem at about the same time, Karl Benz generally is

acknowledged as the inventor of the modern automobile.

An automobile powered by his own four-stroke cycle gasoline engine was built in Mannheim,

Germany by Karl Benz in 1885 and granted a patent in January of the following year under the

auspices of his major company, Benz & Cie., which was founded in 1883. It was an integral design,

without the adaptation of other existing components and including several new technological

elements to create a new concept. This is what made it worthy of a patent. He began to sell his

production vehicles in 1888.

In 1879 Benz was granted a patent for his first engine, which had been designed in 1878. Many of

his other inventions made the use of the internal combustion engine feasible for powering a vehicle.

His first Motorwagen was built in 1885 and he was awarded the patent for its invention as of his

application on January 29, 1886. Benz began promotion of the vehicle on July 3, 1886 and

approximately 25 Benz vehicles were sold between 1888 and 1893, when his first four-wheeler was

introduced along with a model intended for affordability.

They also were powered with four-stroke engines of his own design. Emile Roger of France, already

producing Benz engines under license, now added the Benz automobile to his line of products.

Because France was more open to the early automobiles, initially more were built and sold in France

through Roger than Benz sold in Germany.

In 1896, Benz designed and patented the first internal-combustion flat engine, called a boxermotor in

German. During the last years of the nineteenth century, Benz was the largest automobile company

International Journal of Recent Trends in Engineering & Research (IJRTER) Volume 04, Issue 03; March- 2018 [ISSN: 2455-1457]

@IJRTER-2018, All Rights Reserved 505

in the world with 572 units produced in 1899 and because of its size, Benz & Cie., became a joint-

stock company.

Daimler and Maybach founded Daimler Motoren Gesellschaft (Daimler Motor Company, DMG) in

Cannstatt in 1890 and under the brand name, Daimler, sold their first automobile in 1892, which was

a horse-drawn stagecoach built by another manufacturer, that they retrofitted with an engine of their

design. By 1895 about 30 vehicles had been built by Daimler and Maybach, either at the Daimler

works or in the Hotel Hermann, where they set up shop after falling out with their backers. Benz and

the Maybach and Daimler team seem to have been unaware of each other's early work. They never

worked together because by the time of the merger of the two companies, Daimler and Maybach

were no longer part of DMG.

Daimler died in 1900 and later that year, Maybach designed an engine named Daimler-Mercedes,

that was placed in a specially -ordered model built to specifications set by Emil Jellinek. This was a

production of a small number of vehicles for Jellinek to race and market in his country. Two years

later, in 1902, a new model DMG automobile was produced and the model was named Mercedes

after the Maybach engine which generated 35 hp. Maybach quit DMG shortly thereafter and opened

a business of his own. Rights to the Daimler brand name were sold to other manufacturers.

Karl Benz proposed co-operation between DMG and Benz & Cie. when economic conditions began

to deteriorate in Germany following the First World War, but the directors of DMG refused to

consider it initially. Negotiations between the two companies resumed several years later when these conditions worsened and, in 1924 they signed an Agreement of Mutual Interest, valid until the year

2000. Both enterprises standardized design, production, purchasing, and sales and they advertised or

marketed their automobile models jointly although keeping their respective brands.

On June 28, 1926, Benz & Cie. and DMG finally merged as the Daimler-Benz company, baptizing

all of its automobiles Mercedes Benz as a brand honoring the most important model of the DMG

automobiles, the Maybach design later referred to as the 1902 Mercedes-35hp, along with the Benz

name. Karl Benz remained a member of the board of directors of Daimler-Benz until his death in

1929 and at times, his two sons participated in the management of the company as well.

In 1890, Emile Levassor and Armand Peugeot of France began producing vehicles with Daimler

engines and so laid the foundation of the automobile industry in France. The first design for an

American automobile with a gasoline internal combustion engine was drawn in 1877 by George

Selden of Rochester, New York, who applied for a patent for an automobile in 1879, but the patent

application expired because the vehicle was never built and proved to work (a requirement for a

patent).

After a delay of sixteen years and a series of attachments to his application, on November 5, 1895,

Selden was granted a United States patent (U.S. Patent 549,160 ) for a two-stroke automobile engine,

which hindered, more than encouraged, development of automobiles in the United States. His patent

was challenged by Henry Ford and others, and overturned in 1911.

In Britain there had been several attempts to build steam cars with varying degrees of success with

Thomas Rickett even attempting a production run in 1860. Santler from Malvern is recognized by the

Veteran Car Club of Great Britain as having made the first petrol-powered car in the country in 1894

followed by Frederick William Lanchester in 1895 but these were both one-offs. The first production

vehicles in Great Britain came from the Daimler Motor Company, a company founded by Harry J.

Lawson in 1896 after purchasing the right to use the name of the engines. Lawson's company made

its first automobiles in 1897 and they bore the name Daimler.

In 1892, German engineer Rudolf Diesel was granted a patent for a "New Rational Combustion

Engine". In 1897 he built the first Diesel Engine. Steam-, electric-, and gasoline-powered vehicles

competed for decades, with gasoline internal combustion engines achieving dominance in the 1910s.

Although various pistonless rotary engine designs have attempted to compete with the conventional

piston and crankshaft design, only Mazda's version of the Wankel engine has had more than very

limited success.

International Journal of Recent Trends in Engineering & Research (IJRTER) Volume 04, Issue 03; March- 2018 [ISSN: 2455-1457]

@IJRTER-2018, All Rights Reserved 506

III. DESCRIPTION OF EQUIPMENTS

3.1 COMPRESSOR

A gas compressor is a mechanical device that increases the pressure of a gas by reducing its

volume. Compressors are similar to pumps: both increase the pressure on a fluid and both can

transport the fluid through a pipe. As gases are compressible, the compressor also reduces the

volume of a gas. Liquids are relatively incompressible, so the main action of a pump is to transport

liquids.

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.

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.

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 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.

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) P1V1 =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.

3.2 SOLENOID VALVE:

International Journal of Recent Trends in Engineering & Research (IJRTER) Volume 04, Issue 03; March- 2018 [ISSN: 2455-1457]

@IJRTER-2018, All Rights Reserved 507

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.

Fig 3.2.1

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 & 230 Volts 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

International Journal of Recent Trends in Engineering & Research (IJRTER) Volume 04, Issue 03; March- 2018 [ISSN: 2455-1457]

@IJRTER-2018, All Rights Reserved 508

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.

3.2.1. WORKING OF SOLENOID VALVE:

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.

SOLINOID VALVE (OR) CUT OFF VALVE:

The control valve is used to control the flow direction is called cut off valve or solenoid valve. This

solenoid cutoff valve is controlled by the electronic control unit.

In our project separate solenoid valve is used for flow direction of vice cylinder. It is used to

flow the air from compressor to the single acting cylinder.

3.3 PNEUMATICS

The word ‘pneumatic’ comes from Greek and means breather wind. The word pneumatics is

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

International Journal of Recent Trends in Engineering & Research (IJRTER) Volume 04, Issue 03; March- 2018 [ISSN: 2455-1457]

@IJRTER-2018, All Rights Reserved 509

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.

3.4 CONTROL UNIT:

Here the compressed air form the compressor firstly enters the Control unit. In the control unit the

pressure of the air is controlled unit the pressure of the air is controlled and sent to the solenoid valve

to supply the air to pneumatic gun for the movement of the vehicle using the gear arrangement.

IV. DESIGN OF EQUIPMENT AND DRAWING

4.1 COMPONENTS

The air engine is consists of the following components to full fill the requirements of

complete operation of the machine.

1. Compressor

2. Solenoid valve

3. Control unit

Fig 4.1.1

International Journal of Recent Trends in Engineering & Research (IJRTER) Volume 04, Issue 03; March- 2018 [ISSN: 2455-1457]

@IJRTER-2018, All Rights Reserved 510

Fig 4.1.2

Fig 4.1.3

International Journal of Recent Trends in Engineering & Research (IJRTER) Volume 04, Issue 03; March- 2018 [ISSN: 2455-1457]

@IJRTER-2018, All Rights Reserved 511

DRAWING FOR AIR ENGINE

Fig 5.1

V. WORKING PRINCIPLE

In our project we have operate the vehicle without using the fuel. Inside of fuel we are using the

compressed air supply, with the gear arrangement. Here the vehicle consists of the gear arrangement,

pneumatic gun, solenoid valve and control unit. In this the vehicle wheel shaft is coupled with spur

gear and the pneumatic gun. The air from the compressor it reaches the control unit and the pressure

of air is controlled and it is passed through the solenoid valve. The solenoid valve supply the

required amount of air to the pneumatic gun and the gun shaft the fixed the gear it will be rotate and

the rotating gear is coupled to the wheel shaft gear to move the vehicle. The forced air passes into the

inlet port to rotate the pneumatic gun. Then the output shaft will coupled with the back wheel drive

using gear arrangements which is clearly shown as in the below diagram.

VI. MERITS AND DEMERITS

MERITS

Easy to operate

Air is readily available

Compact

Easy maintenance

DEMERITS

International Journal of Recent Trends in Engineering & Research (IJRTER) Volume 04, Issue 03; March- 2018 [ISSN: 2455-1457]

@IJRTER-2018, All Rights Reserved 512

May be a choice of air leakage

Need for an external powering source at low temperatures.

VII. APPLICATIONS

It is applicable as an alternate to automobile vehicles ,

The engines themselves produce no pollution, so can be used as patient’s vehicle in less fouling surroundings.

The biggest one is that it works underwater and is environmentally friendly.

It is safer compared to internal combustion and electric vehicles because much less heat is generated which can

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 weighed , 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.

International Journal of Recent Trends in Engineering & Research (IJRTER) Volume 04, Issue 03; March- 2018 [ISSN: 2455-1457]

@IJRTER-2018, All Rights Reserved 513

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.

IX. COST ESTIMATION

1. LABOUR COST:

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

2. OVERGHEAD CHARGES:

The overhead charges are arrived by”manufacturing cost”

Manufacturing Cost = Material Cost + Labor Cost =

=

Overhead Charges = 20%of the manufacturing cost

=

3. TOTAL COST:

Total cost = Material Cost +Labour Cost +Overhead Charges

=

=

Total cost for this project =

X. CONCLUSION

The project carried out by us made an impressing task in the field of automobile department. It is

useful for industrial purpose etc..,

This project will reduce the cost involved in the concern. Project has been designed to

perform the entire requirement task at the shortest time available.

BIBLIOGRAPHY I. Design data book -P.S.G.Tech.

II. Machine tool design handbook – Central Machine Tool Institute, Bangalore.

III. Strength of Materials -R.S. Khurmi

IV. Manufaturing Technology -M.Haslehurst.

V. Design of machine elements- R.S. Khurmi