Electro pneumatic bicycle

ELECTRO-PNUEMATIC MOTOR CYCLE

A PROJECT REPORT

Submitted by

PRAVEEN K (1180910066)VIGNESH C (1180910107)VISHNU M (1180910112)

Under the guidance ofMr. SANJAY KUMAR KAR, M.E.

(Assistant Professor, Department of Mechatronics Engineering)

in partial fulfillment for the award of the degreeof

BACHELOR OF TECHNOLOGY

inMECHATRONICS ENGINEERING

of

FACULTY OF ENGINEERING & TECHNOLOGY

S.R.M. Nagar, Kattankulathur, Kancheepuram DistrictMAY, 2013

(A typical specimen of Bonafide Certificate)

SRM UNIVERSITY(Under Section 3 of UGC Act, 1956)

BONAFIDE CERTIFICATE

Certified that this project report titled ELECTRO-PNEUMATIC MOTOR CYCLE is the bonafide work of PRAVEEN K, VIGNESH C, VISHNU M, who carried out the project work under my supervision. Certified further, that to the best of my knowledge the work reported herein does not form any other project report or dissertation on the basis of which a degree or award was conferred on an earlier occasion on this or any other candidate.

SIGNATURE SIGNATURE

Mr. Sanjay Kumar Kar, M.E. Dr. B.K. Vinayagam, Ph.D.

GUIDE HEAD OF THE DEPARTMENTAssistant Professor, Department of MechatronicsDepartment of Mechatronics

Signature of the Internal Examiner Signature of the External Examin

TABLE OF CONTENTS

CHAPTER NO. TITLE PAGE NO.

ABSTRACT iiiLIST OF TABLE xviLIST OF FIGURES xviiiLIST OF SYMBOLS xxvii

1. INTRODUCTION 1

1.1GENERAL 1 1.2 . . . . . . . . . . . . . 2 1.2.1 General 5 1.2.2 . . . . . . . . . . . 12 1.2.2.1 General 19 1.2.2.2 . . . . . . . . . . 25 1.2.2.3 . . . . . . . . . . 29 1.2.3 . . . . . . . . . . . . 30 1.3. . . . . . . . . . .. . . . . . . 45 1.4. . . . . . . . . . . . . . . . . . 58 2. LITERATURE REVIEW 69 2.1GENERAL 752.2 . . . . . . . . . . 992.2 . 100

Chapter 1

Introduction

1.1. Pneumatic vehicle:

1.1.1 Pneumatic bicycle:

The basic requirement of the pneumatic bicycle is to provide a no emission and renewable source of energy used vehicle. Due to time constrain and low budget the best option was to work on a bicycle. To give the initial torque the person has to pedal first once the cycle start moving one can start the throttle letting the air supply to flow in the motor. Since we were low on budget we could come up with the circulatory system which can use the air supplied to the motor again to be compressed and used again for the cycle.

The cylinder containing the compressed air is connected with the flow control valve which controls the flow or air and also cut off the flow of air to stop the cycle. The flow control is connected to the air motor with a pipe. The air motor has a shaft which has a sprocket. This sprocket is connected to the main chain frame system in cycle. So when the air supply is passed through motor the shaft rotate which moves the shaft and sprocket and which in turn moves the main sprocket.

Once the cycle is moved to overcome the initial torque the flow control valve is pushed which helps in letting the air reach the motor which turns the shaft which leads to motion of the cycle. Its a very clean form of source few work has to be done in making a better and much powerful motor. Once the motor is able to overcome torque the cycle moves only on the supply of air. To stop the cycle the flow control valve has to cut off the air supplied to the motor. Since the source of air is stopped the cycle stops moving.

1.1.2 Pneumatic motor: Apneumatic motororcompressed air engineis a type ofmotorwhich doesmechanical workby expandingcompressed air. Pneumatic motors generally convert the compressed air to mechanical work through either linear or rotary motion. Linear motion can come from either a diaphragm or piston actuator, while rotary motion is supplied by either a vane type air motor or piston air motor.

Fig 1.1Pneumatic motors have existed in many forms over the past two centuries, ranging in size from hand held turbines to engines of up to several hundred horsepower. Some types rely on pistons and cylinders, others use turbines. Many compressed air engines improve their performance by heating the incoming air, or the engine itself. Pneumatic motors have found widespread success in the hand-held tool industry and continual attempts are being made to expand their use to thetransportation industry.

There are two types of air motor:1) Linear 2) RotaryLinear:

In order to achieve linear motion from compressed air, a system of pistons is most commonly used.The compressed air is fed into an air-tight chamber that houses the shaft of the piston. Also inside this chamber a spring is coiled around the shaft of the piston in order to hold the chamber completely open when air is not being pumped into the chamber. As air is fed into the chamber the force on the piston shaft begins to overcome the force being exerted on the spring. As more air is fed into the chamber, the pressure increases and the piston begin to move down the chamber. When it reaches its maximum length the air pressure is released from the chamber and the spring completes the cycle by closing off the chamber to return to its original position.

Rotary:

The rotating element is a slotted rotor which is mounted on a drive shaft. Each slot of the rotor is fitted with a freely sliding rectangular vane. The vanes are extended to the housing walls using springs, cam action, or air pressure, depending on the motor design. Air is pumped through the motor input which pushes on the vanes creating the rotational motion of the central shaft. Rotation speeds can vary between 100 and 25,000 rpm depending on several factors which include the amount of air pressure at the motor inlet and the diameter of the housing.

Stored energy in the form of compressed air, nitrogen or natural gas enters the sealed motor chamber and exerts pressure against the vanes of a rotor.This causes the rotor to turn at high speed.

1.2. History:

The pneumatic motor was first applied to the field of transportation in the mid-19th century.Though little is known about the first recorded compressed-air vehicle, it is said that the Frenchmen Andraud and Tessie of Motay ran a car powered by a pneumatic motor on a test track in Chaillot, France, on July 9, 1840. Although the car test was reported to have been successful, the pair didnt explore further expansion of the design.The first successful application of the pneumatic motor in transportation was theMekarski systemair engine used in locomotives. Mekarskis innovative engine overcame cooling that accompanies air expansion by heating air in a small boiler prior to use. TheTramway de nantes, located in Nantes, France, was noted for being the first to use Mekarski engines to power their fleet of locomotives. The tramway began operation on December 13, 1879, and continues to operate today, although the pneumatic trams were replaced in 1917 by more efficient and modern electrical trams.American Charles Hodges also found success with pneumatic motors in the locomotive industry. In 1911 he designed a pneumatic locomotive and sold the patent to theH. k. Porter Companyin Pittsburgh for use in coal mines.Because pneumatic motors do not use combustion they were a much safer option in the coal industry.Many companies claim to be developing Compressed air cars, but none are actually available for purchase or even independent testing.

Fig1.2 Mekarski Tram

1.3. Applications:

A widespread application of small pneumatic motors is in hand-held tools,power ratchet wrenches, drills, sanders, grinders and cutters. Impact wrenches, drills,firearms,die grinders,dental drillsand otherpneumatic toolsuse a variety of air engines or motors. Works are carried out in the field of automobile industry to work on the compressed air engines. Transport category airplanes, such as commercial airliners, use compressed air starters to start the main engines. The air is supplied by the load compressor of the aircrafts auxiliary power unit, or by ground equipment. Water rocketsuse compressed air to power their water jet and generate thrust, they are used as toys. Air Hogs, a toy brand, also uses compressed air to power piston engines in toy airplanes (and some other toy vehicles).1.4. Advantages:Reliability1) Pneumatic systems tend to have long operating lives and require very little maintenance.2) Because gas is compressible, the equipment is less likely to be damaged by shock. The gas in pneumatics absorbs excessive force, whereas the fluid of hydraulics directly transfers force.Safety1) Very low chance of fire.2) Machines can be designed to be overload safe.

Renewable source of energy

1) It is from a renewable source of energy thus not dependent on the fossil fuels production.

No emissions

1) There is no emission if we use a pneumatic controlled system. Since its dependent only on the pressure exerted by the compressed air.

Cost

1) The initial cost of a pneumatic system is very low because these systems are cheap to make and have a simple design composed of inexpensive materials like plastic, zinc or aluminum. However, the long-term operating cost of these systems can be moderate range because it takes a good deal of power to compress enough gas to allow the system to exert a proper amount of pressure.

1.5. Disadvantages:

NoiseThe sound produced when a pneumatic system is installed is very high.

High maintenanceIt requires a lot of care while handling as well as after installation it need a high maintenance.

Oxidation Since air is in contact with the motor there are more chance of the whole system to get oxidized thus damaging the components.

StorageCompressed gas can be stored, allowing the use of machines when electrical power is lost.

Thus we can presume that it has its pros and cons and if worked on it it can prove to be a very vital change in the world of transportation.

CHAPTER 3Design and Fabrication

3.1. Fabrication of motor:

3.1.1 Design Specification:

Before fabrication of Motor, we should consider which motor suits to this required project. While Air-motor is limited in supply, we opted for the air-motor which has ranging from 0.18 to 0.82 HP (0.13 to 0.61 kW) and with motor speeds up to 4000 RPM. It was known as vane-type air motor.

3.1.2 Calculation and specifications:

Specifications of the Air-motor and Air-cylinder.

Torque of the Air-motor = 7Nm Angle of the motor = 3* RPM = 3000 Weight = 3.5 kgs

Air-Cylinder capacity=9L Max. Pressure output from cylinder = 22bar Adjustable up to the level of minimum = 7 bar Weight = 4.5kgs (No air) Weight = 6.5kgs (with air)

Fig 3.1

T1 = Number of teeth in driver T2 = Number of teeth in driven T2 > T1 T1 = 22 T2 = 30 T1 / T2 = N1 / N2Where,

N1 = RPM of driver N2 = RPM of driven N1 = 60 rpm N2 = ?

Torque = DN / 1000*60D = 26 inches (diameter of tyre)D = 660.4 mm

T1/T2 = N1/N2N*22 = 60*30N2 = (60*30) / 22N2 = 81.8181 rpm

= (3.14 * 81.8181 * 660.4)/ (60 * 1000) = 3.46 N/mTorque is 3.46 N/m

We found the torque value and to find the Power loss and Efficiency of the vehicle.

Radius of wheel = 0.25Torque = 3.46 N/mFormulae for power output

Power output = 2**N* / 60Where,N = 1850 rpm of wheel = 3.46N/m (drive generated)By using this values

2*3.14*1850*3.46 / 60 = 669.97 WWe obtained power output 669.97 W

Where to find power input,

Formulae,

Power input = 2**N* / 60Where, N = 3000 rpm of motor = 7N/m of motor

By using this values,

2*3.14*3000*7 / 60 = 2198 WWe obtained the power input 2198 W

Where, Power loss = Power input power out putPower loss = 2198 669.97Power loss = 1528.03 WThe power loss is 1528.03 W

Efficiency = (power output / power input)*100Efficiency = (669.97/ 2198)*100Efficiency = 32.48 %Efficiency of the vehicle is 32.48%

Required calculations are done accordingly.

3.1.3 Fixing the Shaft:

After getting the motor, we observed a small shaft arranged to the motor. We measured the shaft then we obtained those values diameter of half-inch and length 10mm. Those values arent enough to attach a sprocket to that shaft and after thorough study over elongation of shaft to the particular air-motor. Then we attached a required washer to the small shaft and welded it accurately and delicately. Elongation of shaft is done properly before welding a sprocket to the Air-motor.

Fig 3.2

The particular motor doesnt have a silencer over it. We fixed a silencer to the motor to reduce the noise created from the motor while running. Without silencer it creates a whistle sound and it varies after fixing a silencer to the Air-motor. It is must to reduce the noise pollution. Which it was a Go-green project.

Fig 3.3

3.1.4 Fixing the Sprocket:

Before welding a required sprocket to the shaft. We should look over the sprocket teeth requirements. We selected 16 teeth sprocket which resembles the back wheel sprocket which is already fixed. Then we checked the diameter of the hole of sprocket to insert the motors shaft. Shaping of the elongated shaft to fix the sprocket in it. While free-wheeling the bicycle, there was a slight slippage if sprocket from its position. So, we were forced to weld the sprocket too which doesnt affect our pedaling and thereby reduces the friction between sprocket and shaft. The perfect fabrication of motor is done.

The below figure shows the fabrication of motor.

Fig 3.4

3.2. Design of channel:

3.2.1 Placing the Motor:

Fabrication of Air-motor is done. Now mounting the motor to the bicycle is a problematic. Before mounting the motor, we went thoroughly into study of materials and its characteristics. Where Air- motor is made up of cast-iron. Which it doesnt help in welding the motor directly to the bicycle. So, when planning on mounting the Air-motor directly to the back wheel cant be done due to weight ratio problems. When mounting the motor in front of cycle bar requires the welding of motor, which leads to melt the motor where it totally destroys the vane type function of the air-motor. With the other option of mounting the Air-motor at the back carrier portion of the bicycle, which leads to another problematic arrangement of the Air-cylinder to the bicycle. Then there was a final option and the only option for this type of project with limited equipments, where arranging the motor in centre of the bicycle and which helps in the weight ratio of the bicycle by mounting the cylinder on the carrier portion of the bicycle.

3.2.2 Alignment of Sprocket:

For mounting the motor in the centre of the bicycle we need a channel to be arranged to fix the motor in it. Where we made a bridge to fix the motor to sit in it. Then we forged a U-shaped channel bar to sit on the motor. We welded that bar to the bridge accurately. we Arc-welding to this process. This perfect designing of channel leads to nil vibration of the motor and reduces the friction when air is released into the air-motor. Before doing the arc welding, we should make sure that channel, small sprocket and main bicycle big sprocket should be in proper alignment in order to avoid slippage of chain from its position and avoiding sparks too due to friction. Even it helps in proper free-wheeling.Fig 3.5

3.3. Assembly

Before assembly we are selecting flow control valve to fix to the mouth of the Air-cylinder. Where this FCV has two openings, one is for inlet and another one is for outlet. Where in inlet it takes high pressure and from outlet it releases the required pressure to the motor. The actuator is presented on top of the FCV, where we can adjust the pressure of air.

The assembly of the equipments are discussed below.1. Fixing a FCV to the Air-cylinder mouth.2. With help of Male-Female connector we are connecting the FCV to the cylinder.3. Where these pipes are pull-push type and connected directly to the mouth of FCV.4. The other end of the pipe is connected to the inlet of the Air-motor.5. 1M long chain is required to arrange over the sprockets.6. Proper alignment should be checked before arranging the chain for reducing the slippage of the chain.7. Then mounting the Air-cylinder on the back carrier, which was most suitable place for that size.The proper assembly of the equipments to the bicycle can be observed in the below figures.

Fig 3.6

Fig 3.7

3.4. Problems faced during designing

There were numerous problems during the fabrication and designing of the bicycle.1. Required items are very limited in market.2. Material of the motor (cast-iron), doesnt help us in welding it directly.3. Mounting process was a mind boggling process in the project. Where it leads to several other ideas.4. Air-leakage was a problem.5. To vary the output speed and the torque of the motor.6. Connection between the cylinder and FCV.

3.5. Solutions adapted1. As per market survey conducted by us we have selected the components from the other state and made as possible specification as per the design to get the desired power.2. With the use of air tight joints formed by the connectors we prevent the leakage of air.3. We connected the cylinder and FCV directly with help of the Male-Female connector.4. Instead of welding we made a channel for motor to sit in it and mounting process was adjusted by arranging the mid portion of the bicycle to eradicate the weight ratio.Correction Factors

Air pressureOutputSpeedTorqueAir consumption

(Bar)(Psl)

71011.131.011.091.11

6870.940.990.950.96

5730.710.930.790.77

4580.510.850.630.61

3440.330.730.480.44

TABLE 1 CORRECTION FACTORS

Chapter 4Cost EstimationTable 2 S.no.ProductCost

1CycleINR 2200

2MotorINR 3500

3Air Tank and RegulatorINR 7000

4Flow control valveINR 350

5Air Re FilingINR 40

6Direction Control ValveINR

Grand TotalINR 10,030

Chapter 5 Conclusion

The model designed by us is a small scale working model of the Pneumatic controlled bicycle. When it comes to high scale it can used in the motor-bikes for Emission less process.Main advantages of the Pneumatic controlled bicycle are:

1. Zero emission.2. Zero fuel cost (the cost is involved only through air).3. It is both way mechanism (Manual and Pneumatic controlled).4. Affordable price.5. No electricity is needed.

Main disadvantages involved in Pneumatic controlled bicycle are:

1. Less power output.2. Probability Air leakage.3. Slippage of chain at high speeds.4. Acceleration of the bicycle.We can conclude that our project can be utilized for a shorter distance. If a better power motor can be used so that the efficiency of the bicycle can be improved and can be used for longer distance and low emission. Due to time limitation work on motor couldnt be carried out if slight fabricate