Design and Manufacturing of Automobile Vehicle Safety with Pneumatic Bumper

Design and Manufacturing of Automobile Vehicle Safety with Pneumatic Bumper Page No. …..

copyright @ SME 2016 national (Indian)

Paper Name

Design and Manufacturing of Automobile

Vehicle Safety with Pneumatic Bumper

PAPER SUBMITTED BY,

Mr. SHAIKH PARVEZ LATIF

{B.E. MECHANICAL, PUNE}

(Nandgaon, Nashik, Maharashtra, India, PIN: 423106.)

-: Contact :-

Mob.: +91 9822706978

Email ID- “ [email protected] ”

YEAR OF PAPER SUBMISSION

2015-2016


CONTENTS

Sr.No. Content Page no.

1.0 Abstract 01

2.0 Introduction 02

3.0 Problem statement 03

4.0 Objectives 04

5.0 Future scope 05

6.0 Literature review 06

6.1 Safety system 06

6.2 Cushion (energy absorption) 06

6.3 Support (load distribution) 06

6.4 Beam design 07

6.5 Bumper-mounted sensors and/or bumper airbags 07

7.0 Components of project setup 08

7.1 Pneumatic system 08

7.2 Limit switch 08

7.3 IR (infrared) proximity sensor 09

7.4 Electronic relay circuit 10

7.5 Pneumatic power 10

7.6 Braking system 11

8.0 Construction and working 12

9.0 Merits and demerits 13

10.0 Te Technical data 14

11.0 Pneumatic unit 14

12.0 Testing and analysis 15

13.0 Research paper used 16

14.0 References 17


LIST OF FIGURES

Fig. No. Name of figure Page No.

01 Direction of chances Automobile vehicle damage. 03

02 Limit Switch 08

03 IR Proximity Sensor 09

04 Working of IR Proximity Sensor 09

05 Electronic Relay Circuit 10

06 Pneumatic Power System. 10

07 Pneumatic Braking System. 11

08 Experimental Setup 12


1.0 ABSTRACT

The technology of pneumatics plays a major role in the field of automation and modern

machine shops and space robots. The aim is to design and develop a control system based

intelligent electronically controlled automotive bumper activation and automatic braking system

is called automatic pneumatic bumper and break actuation before collision. This project consists

of transmitter and receiver circuit, control unit, pneumatic bumper system and pneumatic

braking system. The is sensor senses the obstacle. There is any obstacle closer to the vehicle

(within 3 - 4 feet); the control signal is given to the bumper activation system and also

pneumatic braking system simultaneously. The pneumatic bumper and braking system is used to

product the man and vehicle. This bumper and braking activation system is only activated the

vehicle speed above 30 - 40 km per hour. This vehicle speed is sensed by the proximity sensor

and this signal is given to the control unit and pneumatic bumper and braking activation system.

In the design of an automobile, a most important task is to minimize the occurrence and

consequences of automobile accidents. Automotive safety can be improved by "active" as well

as "passive" measures. Active safety refers to technology which assists in the prevention of a

crash. Passive safety includes all components of the vehicle that help to reduce the

aggressiveness of the crash event. Crash protection priorities vary with the speed of the car

when crash occurs.


2.0 INTRODUCTION

The purpose of the front/rear bumper system is:

1. To absorb energy at the start of a crash and to guide the remaining crash forces into

the rest of the body structure.

2. At low and medium speed: to minimize the damage of the vehicle in order to reduce

insurance cost.

3. At higher speed: to guide the crash forces into the body structure in such a way that

the probability for a disintegration of the body structure is low and the survival of the

occupants is ensured.

4. To meet the legal (as well as any higher, OEM-specified) requirements regarding the

energy absorbing ability.

Another important function of the front/rear bumper system is the towing

function. This function requires both stiffness and strength. Bumper design concepts

have changed drastically over the last 20 to 30 years. In the past, cars were equipped

with bulky, protruding bumpers to comply with the bumper standards of the 1970s

and early 1980s. More demanding safety regulations and different styling concepts

have resulted in new designs. Styling fashion has drastically changed the visual

appearance of the bumpers. Whereas in the past, bumpers also served as a bright

shiny decorative design element, they are now predominately concealed by a painted

thermoplastic fascia. Since the late 1980s, most bumpers fascia systems are colour

coordinated with the body. {1}.

Then we develop another safety future in vehicle bumper system the aim is to

design and develop a control system based an intelligent electronically controlled

automotive bumper activation system is called “automatic pneumatic bumper”.

There is any obstacle closer to the vehicle (within 4 feet), the control signal after

pressing the extra break switch is given to the bumper activation system.

The pneumatic bumper system is used to product the man and vehicle. This

bumper activation system is only activated the vehicle speed above 40-50 km per

hour. This vehicle speed is sensed by the proximity sensor and this signal is given to

the control unit and pneumatic bumper activation system is activated.


3.0 PROBLEM STATEMENT

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

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

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

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

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

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

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

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

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

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

reduces the damage of both vehicle and passengers. Following fig. shows the Direction of

chances of Impact by percentages and there is 21% of chances Automobile vehicle damage from

frontal area. So, that’s why we worked on Automobile vehicle safety with pneumatic bumper.

Fig.01. Direction of chances Automobile vehicle damage.


4.0 OBJECTIVE

To overcome these unwanted effects we have to Design and Manufacturing of

Automobile Vehicle Safety with Pneumatic Bumper which have following objectives:

1) To increase the sureness of braking Application.

2) To increase the response time of braking system.

3) To improve the pre-crash safety.

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

5) To reduce the requirement of internal safety devices like air bags, that is more costly.


5.0 FUTURE SCOPE

The future scope for the pneumatic bumper mechanism is that it will be available at low

cost and can be provided for the medium scaled vehicles without raising the cost. It will

increase the sureness of braking Application also will increase the response time of braking

system .It will also reduce the requirement air bags for inner safety which costs very high while

manufacturing and also during rewrapping after the damage .


6.0 LITERATURE SURVEY

6.1 SAFETY SYSTEM -

Automobile safety is the study and practice of design, construction, equipment and

regulation to minimize the occurrence and consequences of automobile accidents. Road traffic

safety more broadly includes roadway design. The aim is to design and develop a control system

based on pneumatic breaking system of an intelligent electronically controlled automotive

braking system. Based on this model, control strategies such as an 'antilock braking system'

(ABS) and improved manoeuvrability via individual wheel braking are to be developed and

evaluated.

6.2 CUSHION (ENERGY ABSORPTION) -

The cushion function of the bumper in a pedestrian impact is directly related to the

acceleration impact criterion. It is intended to reduce the severity of bone fractures in a

pedestrian impact. This function is not entirely dissimilar from the traditional function of a

bumper system (absorbing energy of a vehicle impact). But, there are two key differences: the

impact energy and the acceptance criteria. Impact Energy A vehicle-to-vehicle impact requires a

local energy absorption ‘density’ approximately double that of the pedestrian impact, as can be

seen through this brief analysis:

6.3 SUPPORT (LOAD DISTRIBUTION) -

The support function of the bumper system is directly related to the knee bend angle

criterion illustrated. It is intended to reduce the risk of severe knee joint injuries such as

ligament ruptures and intra-articular fractures. The goal is to provide enough support below

and/or above the main bumper to limit the bending moment at the knee joint during an impact.

This situation is complicated by two vehicle design requirements:

• The vehicle damageability standard for bumpers requires the front bumper to be located

at approximately the same height as the pedestrian ‘leg-form’ knee. So without other

support, the greatest bending moment would occur at the knee. This standard also

mandates no damage to other vehicle components, limiting their location.

• The ground clearance and approach angle requirements limit how low to the ground any

components can be located. The goal in the design of bumper components to support the

lower limb during a pedestrian impact is to limit the ‘leg-form’ bending without either,


(i) Sacrificing vehicle damageability,

(ii) Violating vehicle approach angles. The literature and patent review identified

different approaches to meet this goal. As above, these are summarized in order of

decreasing popularity, as measured by the number of patents describing each solution.

An example patent is listed for each.

6.4 BEAM DESIGN -

The design of the bumper beam in a beam-absorber system (traditional passenger car)

has also received some attention. In particular, there are several proposals to change the shape of

the face of the beam to eliminate foam ‘bottoming-out’ and reduce leg form knee bending. In

addition, moulded plastic absorbers often require additional attachment points on he face of the

beam. This represents a common though minor design trend that is really just part of good

design practice.

6.5 BUMPER-MOUNTED SENSORS AND/OR BUMPER AIRBAGS -

The major benefit of this approach is that protecting for pedestrian impact would result

in virtually no change to vehicle styling. In addition, any type of bumper system could be used

with an airbag cover – the energy absorption of the bumper is irrelevant. The key disadvantages

are cost, durability, and feasibility of the system. Sensors and airbags are much more expensive

than most components in other proposals, and their durability outside the vehicle is unknown. In

addition, no sensor has yet demonstrated the performance required to deliver this system. As

these technologies were not reviewed in-depth in this study, insufficient data exists to predict

how likely implementation will be. Major patent activity is on-going in the supporting

technological areas, but the remaining technical hurdles and costs are significant. In the author’s

opinion, implementation will likely be limited to styling-critical vehicles. {2}.

Once the preliminary simulation model has been thoroughly benchmarked and existing

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

provide a basis for comparison of iterative technologies / techniques.

The final phase of the new modern vehicle shall include

• Development of improved ABS control systems

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

• Individual wheel braking combined with traction control

• Assessing sensor failure and fault tolerant control system design.


7.0 COMPONENTS OF PROJECT SETUP

7.1 PNEUMATIC SYSTEM -

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

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

pneumatics is mainly understood to means the application of air as a working medium in

industry especially the driving and controlling of machines and equipment. 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.

7.2 LIMIT SWITCH -

A limit switch is an electromechanical device that consists of an actuator mechanically

linked to a set of contacts. In electrical engineering a limit switch is a switch operated by the

motion of a machine part or presence of an object. They are used for control of a machine, as

safety interlocks, or to count objects passing a point. When an object comes into contact with

the actuator, the device operates the contacts to make or break an electrical connection. Limit

switches are used in a variety of applications and environments because of their ruggedness,

ease of installation, and reliability of operation. They can determine the presence or absence,

passing, positioning, and end of travel of an object. They were first used to define the limit of

travel of an object hence the name “Limit Switch”.

Fig.02. Limit Switch.


7.3 IR (INFRARED) PROXIMITY SENSOR -

The setup of IR sensors module that is to be used on the vehicle’s frontal bumper area to

detect before crash situations which is obtained at receiver of IR (infrared) sensor in terms of

Current & voltage. The signal can be smoothened using to start the automatic safety vehicle

system to absorb and avoid unnecessary crash impact event. {3}.

Fig.03.IR Proximity Sensor.

Fig.04.Fig a,b,c shows how IR sensor

works


Automobile

frontal area with

IR sensor

Relay Circuit

Limit Switch &

Power SupplyPnumatic System

Bracking System

7.4 ELECTRONIC RELAY CIRCUIT -

Circuit is activated only when there is object sense by IR sensor which is present on

front vehicle at speed of automobile vehicle is above in the range of 45 km/h. At this point of

time, the vehicle is traveling in a straight line. The speed of the vehicle has to be regulated

manually to maintain safety. Hence the input of the speedometer is compared with the ideal

value of the speed. If the speed is less than 45 km/h the relay circuit is not active.

Fig.04. Electronic Relay Circuit.

7.5 PNEUMATIC POWER -

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.

Fig.05. Pneumatic Power System.


7.6 BRACKING SYSTEM -

In Automobile Vehicle, The mechanism is often a hand-operated lever on the floor on

either side of the driver, or a pull handle located below and near the steering wheel column, or a

(foot-operated) pedal located far apart from the other pedals. Although sometimes known as an

emergency brake, using it in any emergency where the footbrake is still operational is likely to

badly upset the brake balance of the car and vastly increase the likelihood of loss of control of

the vehicle, for example by initiating a rear-wheel skid. Additionally, the stopping force

provided by using the handbrake instead of or in addition to the footbrake is usually small and

would not significantly aid in stopping the vehicle, again because it usually operates on the rear

wheels; they suffer reduced traction compared to the front wheels while braking. The most

common use for an automobile emergency brake is to keep the vehicle motionless when it

is parked, thus the alternative name, parking brake. Car emergency brakes have

ratchet locking mechanism that will keep them engaged until a release button is pressed. On

vehicles with automatic transmissions, this is usually used in concert with a parking pawl in the

transmission. {4}.

Fig.06. Pneumatic Braking System.


8.0 CONSTRUCTION AND WORKING

Compressed air is used as force medium of this project operation. This compressed air

can be easily taken from the air cylinder of the vehicle used air brake system.The control unit

consists of a relay circuit. It is a photovoltaic sensor switch. It has outputs. The solenoid valve

unit consists of ½ solenoid valves. ½ indicates two ports and one way operation. Compressed

air enters through first solenoid valve and expelled to atmosphere through second solenoid

valve.

Fig.08. Experimental Setup of Automobile Vehicle Safety with Pneumatic Bumper

When driver is in the seat. At that time, the photovoltaic sensor is in open mode. So

current cannot passes to relay circuit through the switch. When driver stands from his seat,

photovoltaic sensor senses and sends electric current to relay circuit. One of the relay output

sends out a voltage to first solenoid valve and now it is in opened position so the compressed air

enters to break chamber. And this time relay stop the current engine coil or motor current.

An additional emergency switch is provided in case of emergency. If the driver needs

bumper, then the emergency switch can be used .It to gives the bottom of break paddle and

provides voltage to the solenoid valve. So the urgent brake is applied .moment gives extra of

paddle these tine limit switch is on and pneumatic bumper is operated forward direction. This

can be used in the case of extreme condition.

The cylinder converts the energy of compressed air into the linear motion. The air enters

the cylinder and pushes the piston from one end of the cylinder to the other. There are two main

types of cylinders-single acting and double acting. A single acting cylinder has only one air

connection while a double acting has two.


9.0 MERITS AND DEMERITS

MERITS

• Quick operation

• Accuracy is more

• It reduces the manual effort.

• Avoid tension of driver

• Emergency parking is available

• Less cost

DEMERITS

• Cylinder stroke length is constant

• Maintenance of the equipment components such as hoses, valves has to

done periodically.


10.0 TECHNICAL DATA

10.1 SOLENOID VALVE

Technical data’s

Size : 0.635x10-2

m

Part size : G0.635x10-2

m

Maximum pressure : 0-10 x10 5

N/m2

Range

Quantity : 2

10.2 HOSES

Technical data’s

Max pressure : 10 x105

N/m2

Outer diameter : 6mm =6 x 10-3

m

Inner diameter : 3.5mm =3.5 x10-3

m

11.0 PNEUMATIC UNIT

11.1 Technical data

Type of cylinder : Double acting

Cylinder

Type of valve : solenoid valve

Max air pressure : 8 x105 N/m

2


12.0 TESTING AND ANALYSIS

It is a simple model. Compressed air at required pressure to stop the vehicle can be taken

from air cylinder of the vehicle, if we used the system in any vehicle that used air brake system

and safety further pneumatic bumper.


13.0 Research Paper Used

Sr.

No

Title Of Paper & Author Page

No.

Objectives Conclusion

1 Applications of Car body

Crash Management Systems

07 Crash Management Bumper systems were originally

installed to protect the engine

and radiator at the front of the

vehicle. A modern front crash

management system, however,

has to fulfill a range of different

additional requirements.

2 Current Trends in Bumper

Design for Pedestrian Impact

Peter J. Schuster

California Polytechnic State

University

12 Bumper Design The deployable approach is to

implement advanced impact

sensors into the bumper and

deploy airbags or structures

over the surface just prior to

impact.

3 Accident Prevention Using

Eye Blinking and Head

Movement

Abhi R. Varma,

Seema V. Arote,

Chetna Bharti,

Kuldeep Singh.

14 Accident Prevention Sensor based control will be the

future of all types of device

control, thus making the

operation so comfortable and

much easier with less human

presence.

4 Automated Vehicle Control

System

M.Habibullah Pagarkar,

Kaushal Parekh,

Jogen Shah,

Jignasa Desai,

Prarthna Advani,

Siddhesh Sarvankar,

Nikhil Ghate.

15 Control System Collision detection and

avoidance systems should

become more commonplace

with the passage of time. People

are living in a networked world

and constantly feel that

they have less time on their

hands.


14.0 REFERENCES

[1] Prof. Mujumdar : “Pneumatics – Study Material”

[2] R. S. Khurmi & I. K. Gupta : “A Textbook or Machine Design”

[3] Prof. H. G. Patil : “Machine Design Data Hand Book (SI Metric)”

[4] Erik Coelingh, etal, “Collision Warning with Auto Brake”, Sweden, ppn: 07-0450.

[5] Dr. Kripal Singh, “Automobile Engineering – Vol. 1”, Standard Publishers Distributors New

Delhi- 110 006

By,

MR. SHAIKH PARVEZ LATIF,

{DME, BE (MECAHANICAL), PUNE, INDIA},

EMAIL ID “ [email protected]”, MOB NO. +91 9822706978.

THANKS FOR READING……………………………………………………………………………… .

Design and Manufacturing of Automobile Vehicle Safety with Pneumatic Bumper

Engineering

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