Automatic 12

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Automatic pneumatic bumper and brake actuation before collision 2015-2016

CHAPTER:-1

INTRODUCTION

1.1AUTOMATIC PNEUMATIC BUMPER AND BRAKE ACTUATION

BEFORE COLLISION

We have pleasure in introducing our new project AUTOMATIC PNEUMATIC BUMPER

AND BRAKE ACTUATION BEFORE COLLISION,which is full!e"uipped b! #$ sensors

circuit and %neumatic bumper and braking activation circuit& #t is a genuine project which is full!

e"uipped and designed for Automobile vehicles& 'his forms an integral part of best "ualit!& 'his

product underwent strenuous test in our Automobile vehicles and it is good&

'he technolog! of pneumatics has gained tremendous importance in the field of workplace

rationali(ation and automation from old-fashioned timber works and coal mines to modern

machine shops and space robots& #t is therefore important that technicians and engineers should

have a good knowledge of pneumatic s!stem) air operated valves and accessories&

A*'+,A'# %./*,A'# *,%/$ A. $A/ A'*A'#+. /3+$/

+44##+.& 'his s!stem is consists of #$ transmitter and $eceiver circuit) ontrol *nit)

%neumatic bumper s!stem and pneumatic braking s!stem& 'he #$ sensor is used to detect the

obstacle& 'here is an! obstacle closer to the vehicle 7with in 8-9 feet:) the control signal is given

to the bumper activation s!stem and also pneumatic braking s!stem simultaneousl!& 'he

pneumatic bumper and braking s!stem is used to product the man and vehicle& 'his bumper and

braking activation s!stem is onl! activated the vehicle speed above 80-90 km per hour& 'his

vehicle speed is sensed b! the pro;imit! sensor and this signal is given to the control unit and

pneumatic bumper and braking activation s!stem&

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1.2 PROBLEM DEFINITION

#n conventional vehicles there are different mechanism operated for braking s!stem like

h!draulic) pneumatic) air) mechanical) etc& ut all these braking mechanisms receive the signal or

input power directl! from the driver so it totall! manual operated& When the driver saw theobstacle or an! vehicle in front of his driving vehicle) he was irritated or becomes ma(!& ue to

this the driver fails to give the proper input to braking s!stem and proper working is not occurs&

Also the driver ma! not able to pa! the full attention during night travelling so there are man!

chances to accidents& After the accident occurs) there is no an! provision to minimi(e the

damages of vehicles& #n currentl! used vehicles generall! bumpers used are of rigid t!pes& 'hese

bumpers have specific capacit! and when the range of the accidental force is ver! high then the

bumpers are fails and these force transferred towards the passengers& o this s!stem never

reduces the damage of both vehicle and passengers& 'o overcome these unwanted effects we

have to design the Automatic raking !stem with %neumatic umpers which have following

objectives

'o increase the sureness of braking Application& 'o increase the response time of braking s!stem& 'o improve the pre-crash safet!& 'o avoid the percentage of passenger injur! b! using e;ternal vehicle safet!& 'o reduce the re"uirement of internal safet! devices like air bags&

1.3 INTRODUCTION TO THE SAFETY SYSTEM

'he aim is to design and develop a control s!stem based on pneumatic breaking s!stem of an

intelligent electronicall! controlled automotive braking s!stem& for comparison of iterative

technologies > techni"ues& 'he final phase of the new modern vehicle shall include?

evelopment of improved A control s!stemsevelopment and assessment of an electro-h!draulic- W 7/


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Fig 1.4 Ai C!"#$%%! & '( #$%%)$ #!*++#i !"#$%%i!

ompressor is the air producing machine& 'he! collect the airs from the atmosphere are in the

running of machine are engine& Air compressors are utili(ed to raise the pressure a volume of air&

Air compressors are available in man! configurations and will operate over a ver! wide range of

flow rates and pressures& ompressed air was e;pelled b! primitive man to give glowing embers

sufficient o;!gen to allow them to flare up into a air& uring the compression process) the

temperature increases as the pressure increases& 'his is known as pol!t!pic compression& 'he

amount of compression power also increases the temperature increases& ompressors are staged

there b! reducing the temperature and improving the compression efficienc!& 'he temperature of

the air leaving each age is cooled prior to entering the ne;t stage& 'his cooling process is called

inter cooling& A metric efficienc! also increases with multi-stage compression since the pressure

ratio over the first stage will be decreased& elections of the air compressor are onl! the first step

in designing an efficient and disable compressed air s!stem& 'he air e;iting the compressor is

saturated with moisture and will have compressor lubricants 7lubricated compressors onl!:&

+ther chemicals that have been drawn into the compressor intake ma! also be present& 'his

contamination harmful to man! processes) pneumatic tools) instruments and e"uipment&

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Air purification e"uipment) filters) air dr!ers) breathing air purifiers) monitoring e"uipment) used

alone or in combination will remove these contaminants& election and purchase of the

compressor and necessar! purification e"uipment can be easil! done on compressed air site& +ur

application engineers are read! to answer all of !our "uestions and to assist !ou in placing !our

order& And it works in the process of rotation fan and the piston movement with the help of

current suppl!&

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POWER SUPPLY

CONTROL UNITIR TRANSMITTER

PNEUMATIC CYLINDER -1

SOLINOID VALVE

BUMPER ENGAGMENT

IR RECEIVER

FLOW CONTROL VALVE

AIR TANK

(COMPRESSOR)

WHEEL SPEED SENSING ARRANGEMENT

PNEUMATIC CYLINDER -2 BRAKING ENGAGMENT


BLOCK DIA/RAM

1.0 BLOCK DIA/RAM OF AUTOMATIC PNEUMATIC BUMPER

AND BRAKE ACTUATION BEFORE COLLISION

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CHAPETR:-2

LITERATURE SUREY

2.1 PNEUMATICS

'he word @pneuma comes from =reek and means breather wind& 'he word pneumatics is the

stud! of air movement and its phenomena is derived from the word pneuma& 'oda! pneumatics

is mainl! understood to means the application of air as a working medium in industr! especiall!

the driving and controlling of machines and e"uipment&

%neumatics has for some considerable time between used for carr!ing out the simplestmechanical tasks in more recent times has pla!ed a more important role in the development of

pneumatic technolog! for automation& %neumatic s!stems operate on a suppl! of compressed air

which must be made available in sufficient "uantit! and at a pressure to suit the capacit! of the

s!stem& When the pneumatic s!stem is being adopted for the first time) however it wills indeed

the necessar! to deal with the "uestion of compressed air suppl!& 'he ke! part of an! facilit! for

suppl! of compressed air is b! 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& ompressor

capacit! is the actual "uantit! of air compressed and delivered and the volume e;pressed is that

of the air at intake conditions namel! at atmosphere pressure and normal ambient temperature&

'he compressibilit! of the air was first investigated b! $obert o!le in 1B62 and that found that

the product of pressure and volume of a particular "uantit! of gas&

'he usual written as

%C D 7or: %ECE D %2C2

#n this e"uation the pressure is the absolute pressured which for free is about 19&F %si and

is of courage capable of maintaining a column of mercur!) nearl! 80 inches high in an ordinar!

barometer& An! gas can be used in pneumatic s!stem but air is the mostl! used s!stem now a

da!s&

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2.2 SELECTION OF PNEUMATICS

,echani(ation is broadl! defined as the replacement of manual effort b! mechanical power&

%neumatic is an attractive medium for low cost mechani(ation particularl! for se"uential 7or:

repetitive operations& ,an! factories and plants alread! have a compressed air s!stem) which iscapable of providing the power 7or: energ! re"uirements and the control s!stem 7although

e"uall! pneumatic control s!stems ma! be economic and can be advantageousl! applied to other

forms of power:&

'he main advantage of an all pneumatic s!stem are usuall! economic and simplicit! the

latter reducing maintenance to a low level& #t can also have outstanding advantages in terms of

safet!&

2.3 PNEUMATIC POER%neumatic s!stems use pressuri(ed gases to transmit and control power& %neumatic s!stems

t!picall! use air as the fluid medium because air is safe) low cost and readil! available&

2.4 T$ A5((g$% !6 P$)"(i%:

1& Air used in pneumatic s!stems can be directl! e;hausted back in to the

surrounding environment and hence the need of special reservoirs and no-leak

s!stem designs are eliminated&

2& %neumatic s!stems are simple and economical&8& ontrol of pneumatic s!stems is easier&

2.0 T$ Di%(5((g$% !6 P$)"(i%:

1& %neumatic s!stems e;hibit spong! characteristics due to compressibilit! of air&

2& %neumatic pressures are "uite low due to compressor design limitations 7less that 250

psi:&

2.7 PRODUCTION OF COMPRESSED AIR

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%neumatic s!stems operate on a suppl! of compressed air) which must be made available in

sufficient "uantit! and at a pressure to suit the capacit! of the s!stem& When pneumatic s!stem is

being adopted for the first time) however it wills indeed the necessar! to deal with the "uestion

of compressed air suppl!& 'he ke! part of an! facilit! for suppl! of compressed air is b! 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& ompressor capacit! is the actual"uantit!

of air compressed and delivered and the volume e;pressed is that of the air at intake

conditions namel! at atmosphere pressure and normal ambient temperature& lean

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&

ompressor ma! be classified in two general t!pes&

1& %ositive displacement compressor&

2& 'urbo compressor

%ositive displacement compressors are most fre"uentl! emplo!ed for compressed air plant and

have proved highl! successful and suppl! air for pneumatic control application&

'he t!pes of positive compressor?

1& $eciprocating t!pe compressor

2& $otar! t!pe compressor'urbo compressors are emplo!ed where large capacit! of air re"uired at low discharge pressures&

'he! cannot attain pressure necessar! for pneumatic control application unless built in

multistage designs and are seldom encountered in pneumatic service&

2.8 RECIPROCATIN/ COMPRESSORS:-

uilt for either stationar! 7or: portable service the reciprocating compressor is b! far the most

common t!pe& $eciprocating compressors lap be had is si(es from the smallest capacities to

deliver more than 500 mG>min& #n single stage compressor) the air pressure ma! be of 6 bar

machines discharge of pressure is up to 15 bars& ischarge pressure in the range of 250 bars can

be obtained with high pressure reciprocating compressors that of three H four stages& ingle

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stage and 1200 stage models are particularl! suitable for pneumatic applications ) with

preference going to the two stage design as soon as the discharge pressure e;ceeds 6 bar )

because it in capable of matching the performance of single stage machine at lower costs per

driving powers in the range &

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CHAPTER:-3

COMPONENTS OF PNEUMATIC BUMPER AND

BRAKIN/ SYSTEM

3.1 PNEUMATIC CYLINDER:-

3.1.1 D!)'*$ (ig +*i$%:

Fig 3.1.1 D!)'*$ Aig P$)"(i C+*i$

A double acting c!linder is emplo!ed in control s!stems with the full pneumatic cushioning and

it is essential when the c!linder itself is re"uired to retard heav! messes& 'his can onl! be done at

the end positions of the piston stock #n all intermediate position a separate e;ternall! mounted

cushioning derive most be provided with the damping feature& 'he normal escape of air is out offb! a cushioning piston before the end of the stock is re"uired& As a result the sit in the cushioning

chamber is again compressed since it cannot escape but slowl! according to the setting made on

reverses& 'he air freel! enters the c!linder and the piston stokes in the other direction at full force

and velocit!&

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3.1.2 GENERALLY USED MATERIALS

C+*i$ T)'$ M($i(*%:

LI/HT DUTY MEDIUM DUTY HEAY DUTY

1& %lastic


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3.1.3 Pi%! M($i(*%:


1&Aluminium

astings

Aluminum astings

rass 73abricated:

Aluminum 3orgings)

Aluminum astings&2& ron(e 73abricated: ron(e 73abricated:8& #ron and teel

astings

rass) ron(e) #ron or

teel astings&

3.1.4 M!) M($i(*%:


1& Aluminum

astings

Aluminum) rass

And teel astings


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Fig 3.1.7 Sig*$ (ig P$)"(i C+*i$

troke length ? !linder stoker length 160 mm D 0&16 m )Juantit!? 1 )eals ? .itride 7una-.:/lastomeric )/nd cones? ast iron) %iston? /. K I ,edia ? Air )'emperature ? 0-I0 L )%ressure

$ange? I .>mM&

'he c!linder is a ingle acting c!linder one) which means that the air pressure operates forward

and spring returns backward& 'he air from the compressor is passed through the regulator which

controls the pressure to re"uired amount b! adjusting its knob& A pressure gauge is attached to

the regulator for showing the line pressure& 'hen the compressed air is passed through the single

acting 8>2 solenoid valve for suppl!ing the air to one side of the c!linder& +ne hose take the

output of the directional ontrol 7olenoid: valve and the! are attached to one end of the

c!linder b! means of connectors& +ne of the outputs from the directional control valve is taken to

the flow control valve from taken to the c!linder& 'he hose is attached to each component of

pneumatic s!stem onl! b! connectors&

3.2 SOLENOID ALE:

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3.2.1 a9 02 D!)'*$ Aig S!*$!i (*5$

'he directional valve is one of the important parts of a pneumatic s!stem& ommonl! known as

C) this valve is used to control the direction of air flow in the pneumatic s!stem& 'he

directional valve does this b! changing the position of its internal movable parts&

'his valve was selected for speed! operation and to reduce the manual effort and also

for the modification of the machine into automatic machine b! means of using a solenoid valve&

A solenoid is an electrical device that converts electrical energ! into straight line motion and

force& 'hese are also used to operate a mechanical operation which in turnoperates the valve

mechanism& olenoids ma! be push t!pe or pull t!pe& 'he push t!pe solenoid isone in whichtheplunger is pushed when the solenoid is energi(ed electricall!& 'he pull t!pe solenoid is one is

which the plunger is pulled when the solenoid is energi(ed&

'he name of the parts of the solenoid should be learned so that the! can be recogni(ed

when called upon to make repairs) to do service work or to install them&

Fig.4.8.1 02 S!*$!i $$ (*5$

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3.2.2 P(% !6 ( 02 S!*$!i (*5$

1.C!i*

'he solenoid coil is made of copper wire& 'he la!ers of wire are separated b! insulating la!er&'he entire solenoid coil is covered with an varnish that is not affected b! solvents) moisture)

cutting oil or often fluids& oils are rated in various voltages such as 115 volts A) 280 volts

A) 960 volts A) 5F5 Colts A) 6 Colts ) 12 Colts ) 29 Colts ) 115 Colts H 280

Colts & 'he! are designed for such fre"uencies as 50


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3.2.3 !;ig !6 S!*$!i (*5$

'he solenoid valve has 5 openings& 'his ensure eas! e;hausting of 5>2 valve& 'he spool of the

5>2 valve slide inside the main bore according to spool positionN the ports get connected and

disconnected& 'he working principle is as follows&

P!%ii!-1

When the spool is actuated towards outer direction port @% gets connected to @ and @ remains

closed while @A gets connected to @$

P!i%ii!-2

When the spool is pushed in the inner direction port @% and @A gets connected to each other and

@ to @ while port @$ remains closed&

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3.2.4 '9 32 SIN/LE ACTIN/ SOLENOID ALE 2 ingle acting solenoid valve is used& +ne solenoid valve

is open>close of vegetable in


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Fig 3.2.4 S!*$!i (*5$ $$


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3.3 HOSE COLLAR AND PU CONNECTOR:-

Fig 3.3 H!%$ A C!**( $$

#n our pneumatic s!stem there are two t!pes of connectors usedN one is the hose connector and

the other is the reducer&


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$educers are used to provide inter connection between two pipes or hoses of different

si(es& 'he! ma! be fitted straight) tee) C or other configurations& 'hese reducers are made up

of gunmetal or other materials like hardened steel etc&

./ 555 monolithic circuit is a highl! stable controller capable of producing accuratetime dela!s or oscillations& Additional terminals are provided for triggering or resetting if

desired& #n the timing operations) the time is precisel! controlled b! one e;ternal resistor and a

capacitor) b! the operation as an oscillator) the free running fre"uenc! and the dut! c!cle are

both accuratel! contributed with the e;ternal $ constants&

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1 8

2 7 IC

NE 555

3 6

4 5


3.4.1 PIN DIA/RAM:

/ROUND SUPPLY


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#t is the output terminal) in low state output is e"ual to (ero and when at higher state output is

e"ual to Ccc&

PIN NO: 4

#t controls the flip flop directl!& #t turns the device to its original position when reset pin is

connected to ground the output is appro;imatel! e"ual to (ero& When reset is not used it is

connected to Ccc&

PIN NO: 0

#t is the control voltage terminal& #t is connected to ground through a capacitor of 0&01 O3& An!

e;ternal voltage at pin? 5 will change both the threshold voltage and the trigger voltage reference

level&

PIN NO: 7

'hreshold voltage of upper comparator is applied from this terminal& 'he resistor $t connected toCcc and pin? 6 is grounded b! an e;ternal capacitor& 'he output is high capacitor charges b!

resistor $t& When the capacitor changes to the threshold level) the output becomes low&

PIN NO: 8

#t is the discharge pin for e;ternal capacitor& *suall! pin? F is connected with pin? 6 directl! to b!

a resistor& When the output becomes low then the e;ternal capacitor discharges b! internal

discharge transistor remains at cut-off and the e;ternal capacitor charges to Ccc&

PIN NO: &

#t is the positive suppl! terminal& A dc voltage from P5 to P 15 can be applied&

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'he important features of #555 can be summari(ed as follows&

'iming range from microseconds to hours& ,ono-stable and A stable operation is possible through #555& 'he dut! c!cle can be adjusted according to our necessit!&

#t has the abilit! to operate from a wide range of suppl! Coltage& 'he output of 555 is compatible with ,+) '4 and ''4) logic& ut when

used with a 5C suppl!& 'riggering and reset inputs are logicall! compatible& +utput can be operated as normal +. and normal +33& 2: D 8 to 6mA

uppl! urrent 7CccD25C>2: D 10 to 15mA

+utput urrent D 200mA 7ma;imum:

%ower dissipation D 600mw

+perating temperature D 0-F0degreeelsius&

3.0 HEEL AND BRAKIN/ ARRAN/EMENT:

Fig 3.0 $$*

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'he simple wheel and braking arrangement is fi;ed to the frame stand &'his wheel 16 inch

diameter of air filled rubber t!res )consist of a 9 wheels are needed& and bearing si(e16mm

inner 82 mm outer and 16mm shaft& 'hese wheels are not fabricated it is purchased&

3.7 STAND:

Fig 3.7, "i* %$$* (**!= #i#$

'his is a supporting frame where wheel are fitted at four corner of the stand made up of mild

steel& ! preparing bod! with this mild steel hallow pipe) after that all parts is to be assembled&

we re"uire 9 feet length and 2 feet width and 1 inch length in each of 9 sides &'he material must

be mild steel of hallow pipe with 1I gauge&

3.8 BUMPER:

Fig 3.8 B)"#$

'his material is made up of a stain less steel and its dimension is 2 feet long 1I mm diameter&

'he material must be purchased this bumper is fitted in front of the vehicle its working is to

resist opposite collision force and it works with the help of single acting pneumatic c!linder&

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3.& IR SENSOR

#$ ased +bstacle etector

Adjustable $ange with %+'

+perating Coltage 5v

ensitivit! up to - 80cm-Adjustable

4ogic output -1>0

Application - #ndustrial safet! devices

Fig 3.& IR S$%! Fig 3.& i)i i(g(" !6 IR S$%!

A sensor is a transducer used to make a measurement of a ph!sical variable& ensor '!pes of

sensor? %assive sensors detect the reflected or emitted electro-magnetic radiation from natural

sources) while active sensors detect reflected responses from objects which are irradiated from

artificiall! generated energ! sources) such as radar& +ptical sensors are characteri(ed specified b!

spectral) radiometric and geometric performance the spectral characteristics are spectral band and

band width) the central wavelength) response sensitivit! at the edges of band) spectral sensitivit!

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at outer wavelengths and sensitivit! of polari(ation& ensors using film are characteri(ed b! the

sensitivit! of film and thetransmittance of the filter) and nature of the lens& canner t!pe sensors

are specified b! the spectral characteristics of the detector and the spectral splitter& #n addition)

chromatic aberration is an influential factor& 'he radiometric characteristics of optical sensors are

specified b! the change of electro-magnetic radiation which passes through an optical s!stem&

'he! are radiometr! of the sensor) sensitivit! in noise e"uivalent power) d!namic range) signal to

noise ratio 7>. ratio: and other noises) including "uantification noise& elements& #3+C is defined

as the angle contained b! the minimum area that can be detected b! a scanner t!pe sensor& 3or

e;ample in the case of an #3+C of 2&5 mille radians) the detected area on the ground willbe 2&5

meters ; 2&5 meters) if the altitude of sensor is 1)000 m above ground& #n our project #$

transmitter and #$ receiver are used to detect the obstacle& 'hese sensors are fitted at the front

side of the vehicle&

3.&.1 IR TRANSMITTER AND IR RECEIER

Fig 3.&.1 IR S$%! R(+%

'he #$ transmitting circuit is used in man! projects& 'he #$ transmitter sends 90 k


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Fig 3.&.2 R$%i%! 4,3>0-R$(%

$esistor is a passive component used to control current in a circuit& #ts resistance is given b! the

ratio of voltage applied across its terminals to the current passing through it& 'hus a particular

value of resistor) for fi;ed voltage) limits the current through it& 'he! are omnipresent in

electronic circuits&

8&I&8 4/

&&&

Fig 3.&.3 LED &,708-R$(%

4ight emitting diodes 74/s: are semiconductor light sources& 'he light emitted from 4/s

varies from visible to infrared and ultraviolet regions& 'he! operate on low voltage and power&

4/s are one of the most common electronic comp&&

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8&I&9 #$ 4/ Q #nfrared 4/

&

Fig 3.&.4 IR LED 17,072-R$(%

An #$ 4/) also known as #$ transmitter) is a special purpose 4/that transmits infrared ra!s

in the range of F60 nm wavelength& uch 4/s are usuall! made of gallium arsenide&&&

8&I&5 %reset

Fig 3.&.0 P$%$10,?&2-R$(%

A preset is a three legged electronic component which can be made to offer var!ing resistance in

a circuit& 'he resistance is varied b! adjusting the rotar! control over it& 'he adjustment can be

done b! using a small screw driver or&&

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3.? RELAY

Fig 3.? $*(+

A $*(+ is an electrical switch that opens and closes under the control of another electrical

circuit& #n the original form) the switch is operated b! an electromagnetto open or close one or

man! sets of contacts& #t was invented b! Roseph


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a capacitor and resistor in series) ma! absorb the surge& #f the coil is designed to be energi(ed

with A) a small copper ring can be crimped to the end of the solenoid& 'his Sshading ringS

creates a small out-of-phase current) which increases the minimum pull on the armature during

the A c!cle&T1U

! analog! with the functions of the original electromagnetic device) a solid-state rela! is made

with a thruster or other solid-state switching device& 'o achieve electrical isolation an opts

couplercan be used which is alight-emitting diode 74/: coupled with a photo transistor&

Fig 3.1> R$*(+ S=iig

3.11 F$()$%

%rinted circuit mounts 10A rela!

1 pole changeover contacts or 1 pole normall! open contact& ,iniature-ugar cube package& coil-860mW& admium 3ree contact material option&

3.12 A5((g$% !6 R$*(+ $ela!s can switch A and ) transistors can onl! switch &

$ela!s can switch high voltages) transistors cannot&

$ela!s are a better choice for switching large currents 7V 5A:&

$ela!s can switch man! contacts at once&

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CHAPTER:4

POER SUPPLY SYSTEM

4.> POER SUPPLY UNIT

A power suppl! is a device or s!stem that supplies electrical or other t!pes of energ! to an output

load or group of loads& 'he term is most commonl! applied to electrical energ! supplies) less

often to mechanical ones) and rarel! to others&

Fig 4.> P!=$ %)##*+ %+%$"

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P!=$ %)##*+ )i !%i%% !6 6!**!=ig )i%

1& tep down transformer

2& $ectifier unit

8& #nput filter

9& $egulator unit

5& +utput filter

4.1 Mi!!!**$ P!=$ S)##*+

#f !ou dont have a power suppl! then !ou should use the following standard circuit&

All !ou will need is a wall power suppl! block with dc output 7greater than IC and no more than

85C: or a BC batter! to plug into .1&

Fig 4.1 Mi! !!**$ #!=$ %)##*+

.ote? #t is best to use the 5C power suppl! circuit as it not onl! correctl! regulates the dc voltage

but it protects !our %# chip& 'he input voltage can go up to 85C without damaging the FI05&

Xou would not want to use that high voltage for ver! long if using reasonable current as the FI05

would have to get rid of the e;cess power as heat& a! !ou used 100mA dropping 85C to 5C

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gives %DC;# D 80 Y0&1 D 8W - a huge power output - the FI05 would get ver! hot and go into

thermal shutdownZ

Fig 4.2 8&>0 5!*(g$ $g)*(!

FI05 is avoltage regulator integrated circuit& #t is a member of FI;; series of fi;ed linear voltage

regulator #s& 'he voltage source in a circuit ma! have fluctuations and would not give the fi;ed

voltage output& 'he voltage regulator # maintains the output voltage at a constant value& 'he ;;

in FI;; indicates the fi;ed output voltage it is designed to provide& FI05 provides P5C regulated

power suppl!& apacitors of suitable values can be connected at input and output pins depending

upon the respective voltage levels&

4.3 PINS OF 8&>0 IC

Pi N! F)i! N("$

1 #nput voltage 75C-1IC: #nput

2 =round 70C: =round

8 $egulated outputN 5C 79&IC-5&2C: +utput

4.4 Si"#*$ 0 #!=$ %)##*+ 6! igi(* i)i%

rief description of operation? =ives out well regulated P5C output) output current

capabilit! of 100 mA

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ircuit protection? uilt-in overheating protection shuts down output when regulator #

gets too hot

ircuit comple;it!? Cer! simple and eas! to build

ircuit performance? Cer! stable P5C output voltage) reliable operation

Availabilit! of components? /as! to get) uses onl! ver! common basic components

esign testing? ased on datasheet e;ample circuit) # have used this circuit successfull!

as part of man! electronics projects

Applications? %art of electronics devices) small laborator! power suppl!

%ower suppl! voltage? *nregulated I-1IC power suppl!

%ower suppl! current? .eeded output current P 5 mA&

.5 BRIEF DESCRIPTION OF OTHER COMPONENTS

1. RESISTORResistor

Fig 4.0 T$$ $%i%!%

'!pe %assive

/lectronic s!mbol

7/urope:

7*:

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A resistor is a two-terminalelectronic componentthat produces avoltageacross its terminals that

isproportionalto the electric currentthrough it in accordance with +hms law?

C D #$

$esistors are elements of electrical networksand electronic circuits and are ubi"uitous in most

electronic e"uipment& %ractical resistors can be made of various compounds and films) as well as

resistance wire 7wire made of a high-resistivit! allo!) such as nickel>chrome:&'he primar!

characteristics of a resistor are the resistance) the tolerance)ma;imum working voltage and the

power rating& +ther characteristics include temperature coefficient) noise) and inductance& 4ess

well-known is critical resistance) the value below which power dissipation limits the ma;imum

permitted current flow) and above which the limit is applied voltage& ritical resistance depends

upon the materials constituting the resistor as well as its ph!sical dimensionsN its determined b!

design& $esistors can be integrated into h!bridandprinted circuits)as well as integrated circuits&

i(e) and position of leads 7or terminals: are relevant to e"uipment designersN resistors must be

ph!sicall! large enough not to overheat when dissipating their power&

4.7 CAPACITOR.

apacitor

Fig 4.7 M!$ (#(i!%, '+ ( " )*$.

'!pe %assive

#nvented / wald =eorg von leist7+ctober 1F95:

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/lectronic s!mbol

A capacitor or condenser is apassive electronic componentconsisting of a pair of conductors

separated b! a dielectric& When a voltagepotential differencee;ists between the conductors) an

electric fieldis present in the dielectric& 'his field stores energ!and produces a mechanical force

between the plates& 'he effect is greatest between wide) flat) parallel) narrowl! separated

conductors&

An ideal capacitor is characteri(ed b! a single constant value) capacitance) which is measured in

farads& 'his is the ratio of the electric charge on each conductor to the potential difference

between them& #n practice) the dielectric between the plates passes a small amount of leakage

current

leakage current& 'he conductors and leads introduce an e"uivalent series resistance and the

dielectric has an electric field strength limit resulting in abreakdown voltage&

apacitors are widel! used in electronic circuits to block the flow of direct current while

allowing alternating current to pass) to filter out interference) to smooth the output of power

supplies) and for man! other purposes& 'he! are used in resonant circuits in radio fre"uenc!

e"uipment to select particular fre"uenciesfrom a signal with man! fre"uencies&

4.8 C$("i (#(i!

#n electronics ceramic capacitor is a capacitor constructed of alternating la!ers of metal and

ceramic) with the ceramic material acting as the dielectric& 'he temperature coefficientdepends

on whether the dielectric is lass 1or lass 2&A ceramic capacitor 7especiall! the class 2: often

has high dissipation factor) high fre"uenc! coefficient of dissipation&

Fig 4.8 $("i (#(i!%

A ceramic capacitor is a two-terminal) non-polar device& 'he classical ceramic capacitor is the

Sdisc capacitorS& 'his device pre-dates the transistor and was used e;tensivel! in vacuum-tube

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e"uipment 7e&g&) radio receivers: from about 1B80 through the 1B50s) and in discrete transistor

e"uipment from the 1B50s through the 1BI0s& As of 200F) ceramic disc capacitors are in

widespread use in electronic e"uipment) providing high capacit! H small si(e at low price

compared to other low value capacitor t!pes&

eramic capacitors come in various shapes and st!les) including?

disc) resin coated) with through-hole leads

multila!er rectangular block) surface mount

bare leadless disc) sits in a slot in the % and is soldered in place) used for *


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4.? T(%i%!

.

Fig 4.? A%%!$ i%$$ (%i%!%.

A transistor is a semiconductor devicecommonl! used to amplif! or switchelectronicsignals& A

transistor is made of a solid piece of a semiconductormaterial) with at least three terminals for

connection to an e;ternal circuit& A voltage or current applied to one pair of the transistors

terminals changes the current flowing through another pair of terminals& ecause the controlled

7output: power can be much more than the controlling 7input: power) the transistor provides

amplificationof a signal& ome transistors are packaged individuall! but most are found in

integrated circuits&

'he transistor is the fundamental building block of modern electronic devices) and its presence is

ubi"uitous in modern electronic s!stems&

4.1> U%(g$

'hebipolar junction transistor) or R') was the most commonl! used transistor in the 1B60s and

F0s& /ven after ,+3/'s became widel! available) the R' remained the transistor of choice

for man! analog circuits such as simple amplifiers because of their greater linearit! and ease of

manufacture& esirable properties of ,+3/'s) such as their utilit! in low-power devices)

usuall! in the,+configuration) allowed them to capture nearl! all market share for digital

circuitsN more recentl! ,+3/'s have captured most analog and power applications as well)

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including modern clocked analog circuits) voltage regulators) amplifiers) power transmitters)

motor drivers) etc

4.11 A5((g$%

'he ke! advantages that have allowed transistors to replace their vacuum tube predecessors in

most applications are

mall si(e and minimal weight) allowing the development of miniaturi(ed electronic

devices&


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4.12 Li"i(i!%

ilicon transistors do not operate at voltages higher than about 1)000 volts7idevices

can be operated as high as 8)000 volts:& #n contrast) electron tubes have been developed

that can be operated at tens of thousands of volts&


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electrons that can leave the base) the number of electrons entering the collector can be controlled&T19Uollector current is appro;imatel! [ 7common-emitter current gain: times the base current& #t

is t!picall! greater than 100 for small-signal transistors but can be smaller in transistors designed

for high-power applications&

*nlike the 3/') the R' is a lowKinput-impedance device& Also) as the baseKemitter voltage

7Cbe: is increased the baseKemitter current and hence the collectorKemitter current 7#ce: increase

e;ponentiall! according to the hockle! diode modeland the /bers -,oll model& ecause of

this e;ponential relationship) the R' has a higher trans conductancethan the 3/'&

ipolar transistors can be made to conduct b! e;posure to light) since absorption of photons in

the base region generates a photocurrent that acts as a base currentN the collector current is

appro;imatel! [ times the photocurrent& evices designed for this purpose have a transparentwindow in the package and are calledphototransistors&

CHAPTER:-0

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DESI/N AND DRAIN/S

0.> PNEUMATIC CYLINDER:

D$%ig !6 Pi%! !:

4oad due to air %ressure&

iameter of the %iston 7d: D 90 mm

%ressure acting 7p: D 6 kg>cm

,aterial used for rod D 95

Xield stress 7!: D 86 kg>mm

Assuming factor of safet! D 2

3orce acting on the rod 7%: D %ressure ; Area

D p ; 7d> 9:

D 6 ; \7 ; 9 )> 9 ]

% D F8&86 g

esign tress7!: D ! > 30

D 86 > 2 D 1I g>mm

D % > 7d> 9 :

d D 9 p > T !U

D 9 ; F5&86 > \ ; 1I]

D 5&88 D 2&8 mm

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,inimum diameter of rod re"uired for the load D 2&8 mm

We assume diameter of the rod D 15 mm

0.1 D$%ig !6 +*i$ i;$%%:

,aterial used D ast iron

Assuming internal diameter of the c!linder D 90 mm

*ltimate tensile stress D 250 .>mmD 2500 gf>mm

Working tress D *ltimate tensile stress > factor of safet!

Assuming factor of safet! D 9

Working stress 7 ft: D 2500 > 9 D 625 g>cm

According to @4A,/ /J*A'#+.

,inimum thickness of c!linder 7 t : D ri \^ 7ftP p: > 7ftK p : -1 ]

Where)

$ i D inner radius of c!linder in cm&

ft D Working stress 7g>cmM:

p D Working pressure in g>cmM

ubstituting values we get)

t D 2&0 \ 7625 P 6: > 7 625 K 6: -1]

t D 0&01B cm D 0&1B mm

We assume thickness of c!linder D 2&5 mm

#nner diameter of barrel D 90 mm

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+uter diameter of barrel D 90 P 2t

D 90 P 7 2 ; 2&5 : D 95 mm

0.2 L$g !6 #i%! !:

Approach stroke D 160 mm

4ength of threads D 2 ; 20 D90mm

/;tra length due to front cover D 12 mm

/;tra length of accommodate head D 20 mm

'otal length of the piston rod D 160 P 90 P 12 P 20

D 282 mm

! standardi(ing) length of the piston rod D 280 mm

0.3 SPECIFICATION

0.3 D!)'*$ (ig #$)"(i +*i$

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Fig 0.3 D!)'*$ Aig P$)"(i C+*i$

T$i(* D((

troke length ? !linder stoker length 160 mm D 0&16 m

Juantit! ? 1

eals ? .itride 7una-.: /lastomeric

/nd cones ? ast iron

%iston ? /. K I

,edia ? Air

'emperature ? 0-I0 L

%ressure $ange ? I .>mM

0.4 Sig*$ (ig #$)"(i +*i$

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Fig 0.4 Sig*$ Aig P$)"(i C+*i$

T$i(* D((

troke length ? !linder stoker length I0 mm D 0&0I m

Juantit! ? 2

eals ? .itride 7una-.: /lastomeric

/nd cones ? ast iron

%iston ? /. K I

,edia ? Air

'emperature ? 0-I0 L

%ressure $ange ? I .>mM

0.0 S!*$!i (*5$

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Fig 0.0 S!*$!i 5(*5$


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T$i(* ((

,a; pressure range ? 0-10 ; 10 .>mM

Juantit! ? 8

0.7 F*!= !!* (*5$

T$i(* D((

%ort si(e ? 0&685 ; 10_M m

%ressure ? 0-I ; 10 .>mM

,edia ? Air

Juantit! ? 1

0.8 C!$!% ( $)$

Fig 0.8 R$)$

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T$i(* ((

,a; working pressure ? 10 ; 10 .>mM

'emperature ? 0-100 L

3luid media ? Air

,aterial ? rass

0.& H!%$%

Fig 0.& H!%$ ( C!**(

T$i(* ($

,a; pressure ? 10 ; 10 .>mM

+uter diameter ? 6 mm D 6 ; 10 Gm

#nner diameter ? 8&5 mm D 8&5 ; 10 G

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0.? ADANTA/ES AND APPLICATIONS

1& 'he outstanding advantage of pneumatic s!stem is the control valve which consistentl!

applies a specified load with minimum effort&

2& 3rom thin foils to metal sheets can be pierced according to desirable shapes&8& #t can be modified to an! e;tend to bring out the re"uired effort&

9& #ts outcome can be utili(ed properl! in the e;tensive mechanical field&

5& ,ultiple c!linder s!stems can be put into action according to the need of pressing

effort&

6& #n modern pa!er plants this pneumatic s!stem can be used for loading press roll&

F& imple construction than the mechanical and h!draulic presses&

I& ompared to h!draulic and mechanical presses pneumatic press is economical&

B& #t does not re"uire current carr!ing cables&

10& .o e;tra skill is re"uired for operating this s!stem&

11& +peration is ver! smooth and in this s!stem we can get more output b! appl!ing less

effort&

12& 'his s!stem can be effectivel! used for punch mark in industrial materials such as

industries name) address or number of product&

0.1> LIMITATIONS


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CHAPTER:-7

BUMPER AND BREAK ACTUATION METHDOLO/Y

7.> ORKIN/ PRINCIPLE

'he compressed air from the compressor at the pressure of 5 to Fbar is passed through a pipe

connected to the olenoid valve with one input& 'he olenoid Calve is actuated with ontrol

'iming *nit& 'he olenoid valve has two outputs and one input& 'he air entering into the input

goes out through the two outputs when the timing control unit is actuated& ue to the high air

pressure at the bottom of the piston) the air pressure below the piston is more than the pressure

above the piston& o these moves the piston rod upwards which move up the effort are) which ispivoted b! control unit& 'his force acting is passed on to punch>rivet which also moves

downwards&

'he punch>rivet is guided b! a punch>rivet guide who is fi;ed such that the punch>rivet is

clearl! guided to the die& 'he materials are in between the punch>rivet and die& o as the

punch>rivet comes down the materials are sheared to the re"uired profile of the punch>rivet and

the blank is moved downwards through the die clearance& When the piston is at the e;treme

point of the stock length) the e;haust valve is opened and the air ise;hausted through itandthepressuri(ed air come in at the top of the piston and it pushes the pistondownwards& o the oneside of the air is pulled downwards and the other side is lifted upwards& o the punch>rivet is

therefore pulled upwards from the die& .ow the piston reaches the bottom point of the re"uired

stroke length& .ow the material is fed and the ne;t stroke of the piston is made read!& When the

material is correctl! positioned then this machine is again actuated automaticall!& 'he time

duration of the succeeding punching is adjusted with the help of control timing unit&

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Fig 7.> i)i i(g(" !6 ')"#$ ( '(;ig %+%$"

7.1 ADANTA/ES

1& #t able to #ncrease the sureness in braking s!stem&

2& raking s!stem able to give fast response&

8& !stem able to increase the pre-crash safet!&

9& !stem able to provide more safet! to the passengers&

5& !stem pla!s an important role to save human

6& 4ife in road accidents&

7.2 LIMITATIONS

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1& !stem has few limitations in densel! traffic road&

2& !stem has no provision to prevent and cure the accidents from rear side of vehicle&

8&


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CHAPTER:-8

IMA/ES

Fig 8.1 Ai !"#$%%!

Fig 8.2 Mi* %$$* (**!= #i#$ )ig

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Fig 8.3 $*ig $ !i%

Fig8.4 P!*i%ig

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Fig 8.0 P(i(* (%%$"'*+

Fig 8.7 C!"#*$$ "!$*

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CHAPTER:-&

&.> ORKED MODEL

Fig:-&.> P$)"(i ')"#$ ( '(;$ ()(i! '$6!$ !**i%i!

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Fig &.1 P$)"(i ')"#$ ( '(;ig ((g$"$

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CHAPTER:-?

CONCLUSION

'his project work has provided us an e;cellent opportunit! and e;perience) to use our limited

knowledge& We are feeling that we have completed the work within time successfull!& 'he

PNEUMATIC BUMPER BRAKE FOR FOUR HEELER is working with satisfactor!

conditions& 'hus we have prepared an PNEUMATIC BUMPER BRAKE FOR FOUR

HEELER which helps to know the how to achieve low cost product&

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CHAPTER-1>

SCOPE FOR FUTURE ORK'he bumper and brake s!stem pla!s a major role in the safet! of an automobile& An automatedsafet! s!stem over manual one is more advantageous in terms of monitoring and deplo!ing incase of accidents& 'he Automatic pneumatic bumper and brake actuation provides this advantageto reduce vehicle damage and save passengers lives& With further improvements) the Automaticpneumatic bumper and brake actuation s!stems use can be e;panded from a small si(e fourwheeler to large trucks and other transportation vehicles& 'his makes it possible to reduce thecatastrophic effects of accidents to a greater e;tent or even eliminate them completel!&

'he idea can be cost effective if used with the e;isting safet! s!stem and makes it more effective

in achieving safet! goals in automotive field&

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Automatic 12

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Transcript of Automatic 12