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POWER GENERATION BY PRODUCTION OF COMPRESSED AIR USING VEHICLE SUSPENSION A project report submitted in partial fullfillment of the requirements for the award of Bachelor of Technology in Mechanical Engineering Under BIJU PATNAIK UNIVERSITY OF TECHNOLOGY, ROURKELA Submitted by : KUNA PATRA REGD.NO-0801210489 RAKESH RAY REGD.NO-0801210489 BHIM CHARAN TUDU REGD.NO-0801210489 SANJAY DUTT BARIK REGD.NO-0801210489 PUSPANJALI MALLICK REGD.NO-0801210489 Under The Esteemed Guidance of Prof. Gopala Krishna Mohanty
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POWER GENERATION BY PRODUCTION OF

COMPRESSED AIR USING VEHICLE SUSPENSIONA project report submitted in partial fullfillment of the requirements for the award of

Bachelor of Technology in Mechanical Engineering

Under

BIJU PATNAIK UNIVERSITY OF TECHNOLOGY, ROURKELA

Submitted by :

KUNA PATRA REGD.NO-0801210489 RAKESH RAY REGD.NO-0801210489

BHIM CHARAN TUDU REGD.NO-0801210489

SANJAY DUTT BARIK REGD.NO-0801210489

PUSPANJALI MALLICK REGD.NO-0801210489

Under The Esteemed Guidance of Prof. Gopala Krishna Mohanty

DEPARTMMENT OF MECHANICAL ENGINEERINGGANDHI INSTITUTE OF ENGINEERING AND TECHNOLOGY

GUNUPUR – 7650222011-12

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Gandhi Institute of Engineering & Technology

GUNUPUR – 765 022, Dist: Rayagada (Orissa), India(Approved by AICTE, Govt. of Orissa and Affiliated to Biju Patnaik University of Technology)

: 06857 – 250172(Office), 251156(Principal), 250232(Fax),

e-mail: [email protected] . visit us at www.giet.org

ISO 9001:2000 Certified Institute

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE This is to certify that the project report entitled “power generation by production of compressed air using vehicle suspension system” is presented by undersigned students in partial fulfillment of the requirements for the 8th Semester Sessional Examination of the degree of Bachelor of Technology in Mechanical Engineering during the academic session 2007-11. This work is submitted to the department as a part of evaluation of 8 th

Semester Project. Kuna patra

Rakesh ray Bhim charan tudu Sanjay dutt barik Puspanjali mallick

Prof.G.K Mohanty Dr. S.P. Chaudhury (Project Guide) (HOD, Mech. Engg.)

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Gandhi Institute of Engineering & Technology

GUNUPUR – 765 022, Dist: Rayagada (Orissa), India(Approved by AICTE, Govt. of Orissa and Affiliated to Biju Patnaik University of Technology)

: 06857 – 250172(Office), 251156(Principal), 250232(Fax),

e-mail: [email protected] . visit us at www.giet.org

ISO 9001:2000 Certified Institute

DEPARTMENT OF MECHANICAL ENGINEERING

ACKNOWLEDGEMENTOur sincere thanks to Prof.(Dr).S.P CHOUDHRY, Head of the Department of Mechanical Engineering, Gandhi Institute of Engineering and Technology, Gunupurfor hisencouragement and valuable suggestions during period of our project work. No words would suffice to express our regard and gratitude to Prof.G.K MOHANTY .,Department of Mechanical Engineering, GIET, Gunupur for his inspiring guidance, constant encouragement, immense support and help during the course of the project.

We express our heartfull gratitude to Principal, GIET, Gunupur for permitting us to carry out this project.

Kuna patra

Rakesh ray

Bhim charan tudu

Sanjay dutt barik

Puspanjali mallick

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CONTENTS

SL.NO TOPIC PAGE NO.

1. ABSTRACT………………………………….

2. INTRODUCTION…………………………….

3. LITERATURE REVIEW………………………

4. OBJECTIVE……………………………………

5. METHODOLOGY ADOPTED…………………

6. MATERIAL IDENTIFICATION……………….

7. SPECIFICATION………………………………….

8. DESIGN CALCULATION…………………………..

9. SCHEMATIC LAYOUT……………………………..

10. APLICATION…………………………………………

11. CONCLUSION…………………………………………

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12. REFERENCES…………………………………………...

13. BIBOLOGRAPHY………………………………………. ABSTRACT

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CHAPTER 1

INTRODUCTION

1.1 OVERVIEW OF RESEARCH

1.1.1 COMPRESSION:

The pressure exerted by a confined gas results from rapid and repeated

bombardmentof the container walls by the enormous number of gas moleculespresent.

The pressure can be increased by increasing the number or force of the collisions.

Increasing the temperature does this by speeding up the molecules (Charles' Law).

Another way is to increase the average number of molecules in a given volume. This

is compression.

It can be done by either decreasing the volume (Boyle's Law) or increasing the

amount of gas. Liquids and solids can be compressed only with difficulty. But gases

are easily compressed because their molecules are relatively far apart and move freely

and randomly within a confined space. Compression decreases the volume available

to each molecule. This means that each particle has a shorter distance to travel before

colliding with another particle or the wall. Thus, proportionately more collisions occur

in a given span of time, resulting in a higher pressure.

1.2 COMPRESSED AIR

Compressed air is air which is kept under a certain pressure, usually greater

than that of the atmosphere. In Europe 10 % of all electricity used by industry is used

to produce compressed air. This amounts to 80 terawatt hours per year.Compressed air

is regarded as the fourth utility, after electricity, natural gas, and water. But per unit

energy delivered, compressed air is more expensive than the other three utilities.

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1.2.1. USES OF COMPRESSED AIR

Pneumatics, the use of pressurized gases to do work. See compressed air energy

storage.

Vehicular transportation using a compressed air vehicle

Energy storage

Scuba diving, to inflate buoyancy devices. 

Cooling using a vortex tube

Gas dusters for cleaning electronic components that cannot be cleaned with

water. These are also called "canned air", however this is a misnomer because

the propellant is not air, but rather a hydro fluorocarbon which poses a health

risk if inhaled.

Air brake (rail) systems

Air brake (road vehicle) systems

Starting of diesel engines (an alternative to electric starting)

Paintball ammunition propulsion

Airsoft ammunition propulsion

Pneumatic air guns

Pneumatic screwdrivers

1.3 PRINCIPLE OF COMPRESSED AIR

The principle of compressed air is compressing the atmospheric air above the

atmospheric pressure by decreasing the volume and increasing the pressure of the air.

The study of compressed air is known as “PNEUMATICS”.

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1.3.1 PNEUMATICS

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.

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.

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The usual written as

PV = C (or) PıVı = P2V2

In this equation the pressure is the absolute pressure 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.

1.4 CONVENTIONAL METHOD OF PRODUCING COMPRESSED AIR

Normally in a conventional method, compressed air is produced using air

compressors. An air compressor operates by converting mechanical energy into

pneumatic energy via compression. The input energy could come from a drive motor,

gasoline engine, or power takeoff.

1.4.1 AIR COMPRESSORS

1.4.1.1 Basic Operation

The ordinary hand bellows used by early smelters and blacksmiths was a simple

type of air compressor. It admitted air through large holes as it expanded. As the

bellows were compressed, it expelled air through a small nozzle, thus increasing the

pressure inside the bellows and the velocity of the expelled air.

Modern compressors use pistons, vanes, and other pumping mechanisms to

draw air from the atmosphere, compress it, and discharge it into a receiver or pressure

system.

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The most basic types of air compressors are designated as “positive

displacement” and “non-positive displacement” (sometimes called “dynamic”). The

characteristic action of a positive displacement compressor is thus a distinct

volumetric change-a literal displacement action by which successive volumes of air

are confined within a closed chamber of fixed volume and the pressure is gradually

increased by reducing the volume of the space. The forces are static-that is, the

pumping rate is essentially constant, given a fixed operating speed. The principle is

the same as the action of a piston/cylinder assembly in a simple hand pump.

1.5 Positive Displacement Compressors

Positive displacement compressors generally provide the most economical

solution for systems requiring relatively high pressures. Their chief disadvantage is

that the displacing mechanism provides lower mass flow rates than non-positive

displacement compressors.

1.5.1 Pressure Characteristics

A compressor with a positive displacement pumping mechanism has these

important pressure characteristics:

The pressure against which the compressor works rises to higher and higher

values as pumping continues. It must be limited by some external pressure

control device.

The rate of free air delivery is highest at 0 psig and very gradually drops to

lower values as pressure increases.

The amount of heat generated progressively rises as pressure increases, causing

substantial increases in temperature of both the air handled and the compressor

structure.

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1.6 Types of Positive Displacement Compressors

Positive displacement compressors are divided into those which compress air

with a reciprocating motion and those which compress air with a rotary motion. The

principal types of positive displacement compressors are the piston, diaphragm,

rocking piston, rotary vane, lobed rotor, and rotary screw.

1.6.1 Reciprocating Piston

The design (Fig. 1.1) is widely used in commercial air compressors because of

its high pressure capabilities, flexibility, and ability to rapidly dissipate heat of

compression and it is oil-less.

Compression is accomplished by the reciprocating movement of a piston within

a cylinder (Fig. 1.2). This motion alternately fills the cylinder and then compresses the

air. A connecting rod transforms the rotary motion of the crankshaft into reciprocating

piston motion in the cylinder. Depending on the application, the rotating crank (or

eccentric) is driven at constant speed by a suitable prime mover. Separate inlet and

discharge valves react to variations in pressure produced by the piston movement.

Fig. 1.2 shows, the suction stroke begins with the piston at the valve side of the

cylinder, in a position providing minimum (or clearance) volume. As the piston moves

to a maximum volume position, outside air flows into the cylinder through the inlet

valve. The discharge valve remains closed during this stroke.

During the compression stroke, the piston moves in the opposite direction,

decreasing the volume of air as the piston returns to the minimum position.

During this action, the spring-loaded inlet and discharge valves are

automatically activated by pressure differentials. That is, during the suction stroke, the

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piston motion reduces the pressure in the cylinder below atmospheric pressure. The

inlet valve then opens against the pressures of its spring and allows air to flow into the

cylinder.

Fig: 1.1Typical reciprocating piston air compressor

Fig: 1.2Reciprocating motion of the piston compresses air with each revolution

Of the crankshaft.

When the piston begins its return (compression) stroke, the inlet valve spring

closes the inlet valve because there is no pressure differential to hold the valve open.

As pressure increases in the cylinder, the valve is held firmly in its seat.

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The discharge valve functions similarly. When pressure in the cylinder becomes

greater than the combined pressures of the valve spring and the delivery pipe, the

valve opens and the compressed air flows into the system.

In short, the inlet valve is opened by reduced pressure, and the discharge valve

is opened by increased pressure.

Some piston compressors are double-acting. As the piston travels in a given

direction, air is compressed on one side while suction is produced on the other side.

On the return stroke the same thing happens with the sides reversed. In a single-acting

compressor, by contrast, only one side of the piston is active.

Single-acting compressors are generally considered light-duty machines,

regardless of whether they operate continuously or intermittently. Larger double-

acting compressors (usually water-cooled) are considered heavy-duty machines

capable of continuous operation.

Sizes of reciprocating piston compressors range from less than 1 hp to 6000 hp.

Good part-load efficiency makes them very useful where wide variations in capacity

are needed.

1.6.1.1 Disadvantages: Reciprocating piston compressors inherently generate inertial

forces that shake the machine. Thus, a rigid frame, fixed to a solid foundation, is often

required. Also, these machines deliver a pulsating flow of air that may be

objectionable under some conditions. Properly sized pulsation damping chambers or

receiver tanks, however, will eliminate such problems.

In general, the reciprocating piston compressor is best suited to compression of

relatively small volumes of air to high pressures.

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1.6.2 Diaphragm

The diaphragm design (Fig. 1.3) is a modification of the reciprocating piston

principle. An outstanding characteristic of the diaphragm design is that the basic

compressing mechanism does not require a sliding seal between moving parts. A

diaphragm compressor is also oil-less and it is therefore often selected when no oil

contamination of the line or atmosphere can be tolerated.

Compression is performed by the flexing of a diaphragm back and forth in a

closed chamber. Fig. 1.4 indicates how this flexing action is generated by the motion

of a connecting rod under the diaphragm. Only a short stroke is required to produce

pressure effects similar to those produced by a reciprocating piston in a cylinder.

Intake and discharge valves convert the volume changes produced by the

reciprocating movement into pumping action. The reed-type valves work like those in

the piston design.

Fig: 1.3 Typical diaphragm compressor. The heavy-duty diaphragm is made

of heat-resistant elastomer with fabric reinforcement.

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Fig: 1.4Cross-section shows diaphragm flexing in response to up/down motionof connecting rod.

Fig:1.5 Dual-chamber diaphragm compressor.

Fig. 1.5 shows a dual-chamber machine. The contour of the diaphragm in the

separatechambers indicates different stroke positions at the same instant. The pressure

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capabilities of the diaphragm compressor are less than those of the piston type, but

usually exceed those of the rotary vane type.

1.6.3 Rocking Piston

The rocking piston principle (Fig. 1.6) is another variation of

reciprocalcompression. In fact, it can be viewed as a combination of the diaphragm

and piston principles.

The rocking piston pump essentially mounts a piston rigidly (no wrist pin) on

top of the diaphragm unit's eccentric connecting rod. This piston is surmounted by a

cup made of Teflon, for instance. The cup functions both as a seal-equivalent to the

rings of a piston compressor-and as a guide member for the rod. It expands as the

piston travels upward, thus maintaining contact with the cylinder walls and

compensating for the rocking motion.

Fig: 1.6The rocking piston principle can be viewed as a combination of thereciprocating piston and diaphragm Ideas.

The rocking piston compressor not only combines the mechanical features of

the reciprocatingpiston and diaphragm types, but it also combines many of their best

performance features. Like the diaphragm type, it is quiet, compact, and oil-less. Like

the reciprocating piston unit, it can provide pressures to 100 psi.

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The absence of a wrist pin is the key to the light weight and compact size of the

rocking piston compressor. This makes the entire piston-connecting rod assembly

much shorter and sharply reduces the overall dimensions and the weight of the unit.

As for durability, the cup is (perhaps surprisingly) more durable than the rings

of a conventional oil-less piston unit. And, on Gast models, when the cup needs

replacing it can be removed and replaced in minutes.

1.6.4 Rotary Vane

Some applications require that there be little or no pulsation in the airoutput and

perhaps a minimum of vibration also. The rotary vane compressor (Fig. 1.7) provides

this. It is commonly used for moderately high air flows at pressures under 30

psig, although some rotary vane designs can provide pressures of 200 psig. Rotary

vane units generally have lower pressure ratings than piston units because of more

difficult sealing problems and greater sensitivity to thermal effects.

Fig. 1.8 shows how pumping action is produced by a series of sliding, flat vanes

as they rotate in a cylindrical case. As the rotor turns, the individual vanes slide in and

out, trapping a quantity of air and moving it from the inlet side of the compressor to

the outlet side.

There are no valves in the rotary vane design. The entire flow of air into and out

of the individual compartments is controlled by the movement of the vanes across

separate inlet and discharge ports.

The rotor is mounted eccentrically -that is, not in the center of the casing. As

the rotor rotates, the vanes are flung outwards and held against the body bore by

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centrifugal and pressure-loading forces. This creates a series of air compartments of

unequal volume (because ofthe rotor's eccentricity). The compartments formed

between adjacent vanes gradually becomelarger during the suction part of the cycle,

and air is drawn into the compartment from the inletport.

Fig:1.7 Typical rotary vane air compressor.

During the discharge portion of the cycle, the compartment volumes gradually

become smaller, compressing the air. When a rotating compartment reaches the

discharge port, the compressed air escapes to the delivery system.

The suction and exhaust flows are relatively free of pulsation because the inlet

and discharge ports do not have valves, and the air is moved continuously rather than

intermittently.

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Fig:1.8 In a rotary-vane compressor, the eccentrically mounted rotor creates smaller compression compartments as the vanes are pushed in by chamber walls.

Rotary vane compressors have certain significant advantages. In addition to

providing smooth, pulse-free air flow without receiver tanks, they are compact (or,

equivalently, offer high flow capacities for a given size), are simple and economical to

install and operate, have low starting and running torque requirements, and produce

little noise or vibration.

1.6.5 Rotary Screw and Lobed Rotor

Two other types of positive displacement compressors are the rotary screw and

lobed rotor. Neither is as widely used, especially in smaller sizes, as are rotary vane

and piston compressors.

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Rotary screw compressors are used when nearly pulse less high-volume air is

required. The compression mechanism is composed of two meshing rotors that have

helical contours. When the rotors are driven at the same speed, air is trapped between

the lobes as the screws turn. The volume between the advancing rotor helix and the

endplate diminishes, forming continuous cavities until the end of the helix passes over

the discharge port.

In a lobed rotor compressor , a pair of mating lobes on separate shafts rotates in

opposite directions to trap incoming air and compress it against the casing. Lobed

rotor units provide very high air flows at pressures between those of non-positive

displacement compressors and other types of positive displacement units.

1.7 Non-positive Displacement Compressors

Non-positive Displacement Compressors also called "dynamic," "continuous-

flow," and "velocity-type" compressors, this category comprises machines that use

changes in kinetic energy to create pressure gradients.

Kinetic energy is the energy that a body possesses by virtue of its motion. A

fluid's kinetic energy can be increased either by rotating it at high speed or by

providing an impulse in the direction of flow.

Unlike the positive displacement compressor, in which distinct volumes of air

are isolated and compressed, a non-positive displacement compressor does not

provide a constant-volume flow rate over a range of discharge pressures. This is

because the compartments are not isolated from each other and leakage between them

increases as pressure rises.

Initial acceleration of the air produces a negative (suction) pressure at the inlet

port, drawing air in. Partial deceleration of air at the discharge port converts some of

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the kinetic energy to pressure. Speed of the rotating impeller determines the pressure

change. Higher-pressure differences require either faster impeller speeds or additional

stages.

The most important advantage of non-positive displacement machines is their

ability to provide very high mass flow rates. On the other hand, multiple stages are

required to provide pressures above 4 or 5 psi and such machines are cost effective

only for flow rates above 80-100 cfm.

Non-positive displacement devices are sometimes called fans or blowers rather

than compressors. By some definitions, a fan provides less than 0.5 psi pressure and a

blower between 0.5 and 10 psi. The distinction is frequently blurred in common use,

however.

The three common types of non-positive displacement compressors are

centrifugal, axial, and peripheral (or regenerative). These names derive from the

direction of air flow through their compression chambers.

1.7.1 Centrifugal Compressors

Centrifugal compressors are best suited to the continuous movement of large air

volumes through small pressure ranges. Fig. 1.9 shows the basic operation. Air

leaving a rotating impeller passes radially outward to the casing. Centrifugal action

builds up velocity and pressure levels.

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Fig: 1.9 In a centrifugal blower, a rotating impeller sweeps air radially alongthe casing to the outlet.

In its simplest form, a centrifugal compressor consists of a high-speed rotating

impeller that receives air through an inlet nozzle at the center. The impeller vanes are

fixed (unlike those in the rotary vane design). They throw the air centrifugally

outward toward the casing, increasing its velocity and energy. Here, an outlet

discharges the air into a stationary passageway known as a "diffuser." The diffuser

reduces the air velocity, thus raising the pressure. Beyond the diffuser, the velocity

may be further reduced and pressure increased by a "collector."

Staging can yield higher pressures. Staging is accomplished by directing the

output from the diffuser of one stage into the nozzle of the next.

Because the flow from the impeller is continuous, a smooth, surge-free output is

obtained. Furthermore, discharge pressure depends only on impeller speed. It is nearly

constant, despite variations in flow, over the stable operating range.

But this can be a drawback if the demand falls far enough below the rated flow,

allowing system pressure to build up. The compressor continues to deliver air at about

the same pressure until the back-pressure exceeds that developed by the compressor.

The result is "surge"-a reversal of flow. This reversal immediately allows the back-

pressure to go down, and regular compression is resumed.

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Surge can be prevented if flow remains above a limit established for each

design. Various models have minimum operating flows between 45 and 90 percent of

rated capacity.

Centrifugal compressors are available in both small and very large sizes. Units

with up to six stages and supplying 30,000 cfm of air are commercially available.

Operating speeds are very high compared with other types-up to 20,000 rpm in

standard applications.

1.7.2 Axial Flow

Fig: 1.10 Air flows (arrows) through multistage axial flow blower. The fixedguide vanes between each stage keep air flow parallel to the axis of

rotation.

This category is generally used for ultrahigh flow applications (30,000 to

1,000,000 cfm). Air flow is through a duct, primarily in a direction parallel to the axis

of rotation. In multistage versions, this flow channelling is provided by the fixed guide

vanes or stator blades positioned between each stage (Fig. 22). An axial flow

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compressor requires about a third the floor space of a centrifugal design, and it weighs

about a third as much. Below capacities of 100,000 cfm, though, the axial design is

seldom competitive in price.

1.8 Multistage Compression

Compression may be accomplished in one or more stages. That is, air can be

compressed once or several times before it reaches the compressor outlet and is

delivered to the system devices. Each stage provides a proportional increase in the

output pressure. Positive displacement compressors have the advantage of providing

relatively large pressure changes in a single stage, and very large pressure changes in

a few stages. However, the pressure output of nonpositive displacement compressors

can also be raised by staging.

1.8.1 Single Stage

Fig. 1.11 is another way of illustrating how the compression process is carried

out in a single pass through a pumping chamber. This piston-type compressor has two

cylinders, but the compression action occurs in a single stage. The cylinders are

connected in parallel between the atmosphere and the discharge manifold.

The normal maximum pressure rating for single-stage compressors is about 100

psig. Operation above this level increases the heat of compression (caused by leakage

andrecompression) to levels that could harm the compressor and the overall system.

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Fig: 1.11 Basic operation of a single stage/two cylinder air compressor.

1.8.2 Multiple Stage

In multiple-stage compression, the gas moves from one chamber to another.

This sequential action provides the final pressure.

For general utility and process purposes, two-stage compression is usually

justified when the compression ratio (R,) exceeds six. When Rc exceeds 20,

compression is usually accomplished in three stages. To put this in pressure units, the

upper limit for utility two-stage compressors is between 280 and 300 psig. A gauge

pressure of 500 psi has an RC value of 35.

Some multistage compressors eliminate the problem of increased heat of

compression above 100 psig. This is done by:

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Compressing the air to an intermediate pressure in the large-diameter low-

pressure cylinder.

Removing a portion of the heat of compression before the air is fed to the next

stage (this is known as "intercooling" and is normally done by an air-cooled

or water-cooled heat exchanger).

Further compressing the air to final pressure in a smaller high-pressure cylinder.

Fig:1.12 Basic operation of two stage/two cylinder air compressor

As Fig. 20 shows, these two cylinders are connected in series through the

intercooler (compare with Fig. 19). Intercooling greatly decreases both the total

temperature rise of the compressed air and the amount of work required for its

compression. But the added cost of an intercooler cannot always be justified on a

small compressor. Some two-stage compressors have three cylinders: two low-

pressure cylinders connectedto one high-pressure cylinder through an intercooler.

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CHAPTER 2

LITERATURE SURVEY

2.1 COMPRESSED AIR PRODUCTION

2.1.1 COMPRESSED –AIR-TO-ELECRIC POWER SYSTEM

1 Title: Design considerations and experimental results of a 60W of compressed air

to electric power system

Authors: D. Krahenbuhl , C Zwyssig , H. Horler and J. W. Kolar Power Electronic

Systems Laboratory, ETH Zurich, Switzerland, Aerothermochemistry and

Combustion Systems Laboratory,ETH Zurich, Switzerland

Inference: In many process applications, where a pressure reduction is required the

energy ends up being dissipated as heat. Examples are throttling valves of gas

pipelines and automotive engines or turbo expanders as used in cryogenic plants. With

a new pressure reduction system that produces electricity while expanding the gas, this

lost energy can be recovered.

To achieve a high power density this energy generation system requires an

increased operating speed of the electrical machine and the turbo machinery.

This paper proposes a miniature compressed air-to electric-power system, based on a

single-stage axial impulse turbine with a rated rotational speed of 350 000 rpm and a

rated electric power output of 60 W. A comprehensive description including turbine

and permanent magnet (PM)

generator is given and measurements like maximum electric output power of 124W

and maximum system efficiency of 24 % are presented. This paper shows the design

and measurement results of a compressed-air-to- electric power system. The described

system has been optimized concerning power density (4.4 W/cm3) and system

efficiency (system = 24 %);

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The computed and measured values are significantly higher compared to similar

systems described in literature so far. Also the generator efficiency (87 %) is

significantly higher compared to [8] (58 %) and [9] (28 %), respectively. The better

efficiencies can be achieved by system integration, generator optimization and careful

design of the turbine. Due to the miniaturization, the isentropic efficiency cannot be

predicted analytically and has been verified experimentally. Measurements show that

the system has a maximum power output of 124 W at 370 000 rpm and a maximum

efficiency of 24 % at 350 000 rpm.

2 Title: A Compressed Air Tank for a Lorry

Author: Åke Karlsson, Gränges Technology Service (GTC), Finspång

and by Skanaluminium, Oslo

Inference: Drivers of heavy vehicles such as lorries and buses require extra power to

perform certain functions, including: Braking, Steering, Gearing and differential

blocking ,Clutching, Exhaust braking, Seat suspension/regulation, Suspension,

Braking the trailer, Pneumatic, hydraulic and electrical systems are all used to provide

the added power, needed.

Pneumatic power-enhancement is commonly used for the braking systems of

lorries due to its: Reasonable cost Excellent reliability, Long life Simple maintenance

Familiar technology We are going to manufacture a container for the storage of

compressed air in a pneumatic braking system for buses and lorries. Because of the

complex requirements, we didn't have many alternatives to evaluate in this example.

We looked at a solution in steel and one in aluminium, both of which satisfied the

requirements. luminium was chosen because it could be used to make a product that

performed its function better than steel.

Although this solution is considerably more expensive to manufacture, it will

save money in the long run-in view of the fact that we also achieve a higher level of

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safety, we have clearly selected the best solution. Using aluminum to manufacture

compressed air tanks has turned out very well.

The product example described here is still competitive. The product could

probably be improved even further if the CEN standards had not limited our choice of

alloy and material thickness. Both solutions satisfy our requirements. Our choice will

therefore dependon how we choose to rank the evaluation criteria. In this case, weight

savings, reliability and low maintenance costs weigh so heavily that we opt for

aluminum.

3 Title: Reciprocating-Piston Compressor Having Non-Contact Gap Seal

Author: Michel Rigal ,Gilles Hebrard,Crowell & Moring Llp;Intellectual Property

Group

Inference: A reciprocating-piston compressor having at least two working cylinders

arranged in series, along a cylinder axis is described. The compressor includes a

piston in each of the cylinders, guided in an axially movable manner, and a common

axially actuated piston rod of the pistons, extending through a passage opening in a

partition between the at least two working cylinders.

The at least two working cylinders are sealed off with respect to one another in

a region of the common axially actuated piston rod, exclusively by a non-contact seal.

The axial seal has an axial gap seal formed between a radially outer circumferential

surface of the common axially actuated piston rod and a radially inner circumferential

surface of the passage opening.

The invention includes a reciprocating-piston compressor having at least two

working cylinders which are arranged in series and along a cylinder axis and in which

in each case one piston is guided in an axially movable manner, with the pistons

having a common axially actuated piston rod which extends through a passage

opening in a partition between the working cylinders.

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In the reciprocating-piston compressors known from the prior art, a contact seal

in the form of a sealing ring is conventionally provided between the passage opening

and the piston rod, in order to seal off the working cylinders, which are arranged in

series, with respect to one another. In particular where reciprocating-piston

compressors are used in compressed-air brake systems of utility vehicles such as

commercial trucks, a high compressor power is required on account of the high

compressed air demand, and the reciprocating-piston compressor must therefore

perform a high number of compression strokes.

The previously-used contact seals, however, generate friction, such that

relatively high friction losses are generated as a result of the high number of

compression strokes, which friction losses also manifest themselves in high

temperatures of up to 300° C. in the region of the seal. For these reasons, a low-

friction and simultaneously heat-resistant material is necessary for the seals, which is

correspondingly expensive.

4. Title: Compressor unit for a vehicle air suspension system

Authors: Marc-Michel Bodet  Ludger Frilling  Frank Meissner

Kramer Levin Naftalis & Frankel Llp;Intellectual Property Department

Inference: A compressor unit for an air suspension system of a motor vehicle, having

a compressor, an air dryer and a compressed-air port for delivering compressed air

from the compressor to the air suspension system and for introducing compressed air

from the air suspension system into the air dryer. A ventilation line is provided from

the air dryer to the environment of the compressor. The ventilation line has an

upwardly convex bend when the compressor unit is in installed position.

The present invention relates generally to a compressor unit for a motor vehicle

air suspension system, including a compressor, an air dryer and a compressed-air port

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for delivering compressed air from the compressor to the compressed air system and

for returning compressed air from the air suspension system into the air dryer.

Motor vehicle compressor units of the general type under consideration are

arranged, for example, in the region of the rear axle below the vehicle's luggage

compartment, and provide compressed air, for example, for a level control system of

the vehicle's air suspension system. In, for example, all-terrain vehicles, which can

travel through bodies of water as long as the water remains below a fording line, to

prevent the air spring system with the compressor unit from icing, the compressed air

must remain dry even when the vehicle is travelling through water or when the outside

temperature falls.

However, with conventional compressor units, instances of icing can occur in

the worst case, particularly when the compressor units are used in vehicles in which

only small air quantities are moved for the purpose of level control. Generally

speaking, in accordance with embodiments of the present invention, a compressor unit

for a vehicle air suspension system, including a compressor, an air dryer and a

compressed-air port, is provided which overcomes disadvantages associated with

conventional compressor units.

To reduce the tendency of the entire vehicle air spring system to ice, even

under unfavorable environmental conditions, the present invention provides a

compressor unit in which the ventilation line from the air dryer to the environment of

the compressor has an upwardly convex bend when the compressor unit is

installed.Because of the convex bend, it is possible to dispense with the conventional

long ventilation hose extending above the fording line. The convex bend ensures that,

in the event of a discharge of compressed air out of the air suspension system, the air

dryer is regenerated and the ejected, moist air always leaves the short ventilation hose.

This is achieved even if only a small amount of air is discharged during ventilation,

for example, on account of the downstream air suspension system requiring only a

small amount of compressed air.

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CHAPTER 3

OBJECTIVE

The sole purpose of this project is to find a simple but improved design with good mechanical advantage in substitute of electricity. Some of the specific objectives are:

To eliminate the use of electrical energy, fuel input for the production of compressed air.

To produce compressed air using non-conventional method instead of using conventional method.

To develop a portable-type air compressor

To utilize the vehicle suspension for production of compressed air.

To utilize the compressed air for the generation of electricity.

To run an aluminium turbine using the compressed air pressure and velocity thus by running a DC generator connected by means of shaft to produce a small amount of DC current.

To store the little amount of DC current produced, by using it to charge a 12 V DC battery.

To use a 12 V DC to AC inverter to convert direct current to alternating current.

To glow a 40 Watts fluorescent lamp using the AC output from the inverter

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CHAPTER-4

METHODOLOGY AND MATERIAL IDENTIFICATION :

4.1 METHODOLOGY ADOPTED

Figure 4.1 Methodology adopted

Literature Survey

Layout of the model

Requirement of components

Design calculations

Identification of appropriate materials

Machining requirements of the components

Building of the base frame

Assembling of the components

Checking the performance of the model

Developing the final product

Problem identification and solution

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4.2 COMPONENTS AND MATERIAL IDENTIFICATION

4.2.1 VEHICLE FRAME AND PNEUMATIC CYLINDER:

This is made up of mild steel. The model vehicle frame is made up of mild steel

pipe material. The suspension action is given by the pneumatic cylinder.

Mild and low carbon steel:

Mild steel is the most common form of steel because its price is relatively low

while it provides material properties that are acceptable for many applications. Low

carbon steel contains approximately 0.05–0.15% carbon and mild steel contains 0.16–

0.29% carbon.

Properties of mild steel:

It can be easily machine able.

The density of mild steel is approximately 7.85 g/cm3.

Its Young's modulus is 210,000 MPa

it is neither brittle nor ductile

Mild steel has a relatively low tensile strength

it is cheap and malleable

surface hardness can be increased through carburizing

The cylinder is a Single acting cylinder one, which means that the air pressure

operates forward and spring returns backward. The air from the compressor is passed

through the regulator which controls the pressure to required amount by adjusting its

knob. A pressure gauge is attached to the regulator for showing the line

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pressure.Then the compressed air is passed through the single acting 3/2 solenoid

valve for supplying the air to one side of the cylinder.

One hose take the output of the directional Control (Solenoid) valve and they

are attached to one end of the cylinder by means of connectors. One of the outputs

from the directional control valve is taken to the flow control valve from taken to the

cylinder. The hose is attached to each component of pneumatic system only by

connectors.

4.2.2 CYLINDER TECHNICAL DATA

Piston Rod : M.S. hard Chrome plated

Seals : Nitrile (Buna – N) Elastomer

End Covers : Cast iron graded fine grained from

. 25mm to 300mm

Piston : mild steel.

Medium : Air.

Temperature Range : 0◦c to 85◦c

Cylinder Tube Materials:

LIGHT DUTY MEDIUM DUTY HEAVY DUTY

Plastic Hard drawn brass tube Hard drawn brass tube.

Hard drawn Aluminum

tubeAluminum Castings Hard drawn steel tube

Hard drawn brass tube Brass, Bronze, IronCastings, welded steel

tube

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4.2.2.1 Parts of Pneumatic Cylinder

4.2.2.1.1 Piston:

The piston is a cylindrical member of certain length which reciprocates inside

the cylinder. The diameter of the piston is slightly less than that of the cylinder bore

diameter and it is fitted to the top of the piston rod. It is one of the important parts

which convert the pressure energy into mechanical power.

Piston Materials:LIGHT DUTY MEDIUM DUTY HEAVY DUTY

Aluminum Castings Aluminum Castings Aluminum Forgings

Aluminum Castings Bronze (Fabricated) Bronze (Fabricated)

Brass (Fabricated) Iron and Steel CastingsBrass, Bronze, Iron or

Steel Castings.

The piston is equipped with a ring suitably proportioned and it is relatively soft

rubber which is capable of providing good sealing with low friction at the operating

pressure. The purpose of piston is to provide means of conveying the pressure of air

inside the cylinder to the piston of the oil cylinder.

Generally piston is made up of

Aluminum alloy-light and medium work.

Brass or bronze or CI-Heavy duty.

The piston is single acting spring returned type. The piston moves forward

when the high-pressure air is turned from the right side of cylinder. The piston moves

backward when the solenoid valve is in OFF condition. The piston should be as

strong and rigid as possible. The efficiency and economy of the machine primarily

depends on the working of the piston. It must operate in the cylinder with a minimum

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of friction and should be able to withstand the high compressor force developed in the

cylinder and also the shock load during operation.

The piston should posses the following qualities.

a. The movement of the piston not creates much noise.

b. It should be frictionless.

c. It should withstand high pressure.

4.2.2.1.2 Piston Rod

The piston rod is circular in cross section. It connects piston with piston of

other cylinder. The piston rod is made of mild steel ground and polished. A high

finish is essential on the outer rod surface to minimize wear on the rod seals. The

piston rod is connected to the piston by mechanical fastening. The piston and the

piston rod can be separated if necessary.

Piston Rod Materials:

MATERIAL FINISH REMARKS

MILD STEEL

Ground and polished

hardened, ground and

polished.

Generally preferred

chrome plated

STAINLESS STEEL Ground and Polished

Less scratch resistant

than chrome plated

piston rod

One end of the piston rod is connected to the bottom of the piston. The other

end of the piston rod is connected to the other piston rod by means of coupling. The

piston transmits the working force to the oil cylinder through the piston rod. The

piston rod is designed to withstand the high compressive force. It should avoid

bending and withstand shock loads caused by the cutting force. The piston moves

inside the rod seal fixed in the bottom cover plate of the cylinder. The sealing

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arrangements prevent the leakage of air from the bottom of the cylinder while the rod

reciprocates through it.

4.2.2.1.3 Cylinder Cover Plates

The cylinder should be enclosed to get the applied pressure from the

compressor and act on the pinion. The cylinder is thus closed by the cover plates on

both the ends such that there is no leakage of air. An inlet port is provided on the top

cover plate and an outlet ports on the bottom cover plate.

End Cover Materials:

LIGHT DUTY MEDIUM DUTY HEAVY DUTY

Aluminum stock

(Fabricated)Aluminum stock (Fabricated) Hard tensile

. Brass stock

(Fabricated). Brass stock (Fabricated) Castings

Aluminum Castings Aluminum , Brass iron or steel Castings

There is also a hole drilled for the movement of the piston. The cylinder cover

plate protects the cylinder from dust and other particle and maintains the same

pressure that is taken from the compressor. The flange has to hold the piston in both

of its extreme positions. The piston hits the top plat during the return stroke and hits

the bottom plate during end of forward stroke. So the cover plates must be strong

enough to withstand the load.

4.2.2.1.4 Seal:

This is a thin inner layer in the inner circumference of the cylinder bore in order

to reduce the wear and tear between piston and cylinder .this is made of nitrile

elastomer.

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Nitrile rubber is the most commonly used elastomer for O-rings and other

sealing devices. Also known as Buna N, nitrile is a copolymer of butadiene and

acrylonitrile (ACN). The name Buna N is derived from butadiene and natrium (the

Latin name for sodium, the catalyst used in polymerizing butadiene). The “N” stands

for acrylonitrile.

The butadiene segment imparts elasticity and low temperature flexibility. It also

contains the unsaturated double bond that is the site for crosslinking, or vulcanization.

This unsaturated double bond is also the main attack site for heat, chemicals, and

oxidation. The acrylonitrile segment imparts hardness, tensile strength, and abrasion

resistance, as well as fuel and oil resistance.

Heat resistance and gas impermeability are also improved through increased

ACN content, which typically ranges from 18% to 45%. A standard, general-purpose

nitrile compound usually contains 34% CAN.

4.2.2.1.4 Cylinder Mounting Plates:

It is attached to the cylinder cover plates and also to the carriage with the help

of ‘L’ bends and bolts.

Mount Materials:

LIGHT DUTY MEDIUM DUTY HEAVY DUTY

1. Aluminum

Castings

Aluminum, Brass & Steel

Castings

High Tensile Steel

Castings

2. Light Alloy

(Fabricated)Steel Fabrication

High Tensile

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4.2.3 PU CONNECTIORS, REDUCER AND HOSECOLLAR:

In our pneumatic system there are two types of connectors used; one is the hose

connector and the other is the reducer. Hose connectors normally comprise an adapter

(connector) hose nipple and cap nut. These types of connectors are made up of brass

or Aluminum or hardened steel. Reducers are used to provide inter connection

between two pipes or hoses of different sizes.

They may be fitted straight, tee, “V” or other configurations. These reducers

are made up of gunmetal or other materials like hardened steel etc.

4.2.3.1 Hose pipe:

Hose-pipe, or simply " hose," the name given to flexible piping by means of

which air may be conveyed from one place to another. One end of the pipe is

connected to the source of the air, while the other end is free, so that the direction of

the flow of air which issues from the pipe may be changed at will.

The method of manufacture and the strength of the materials used depend

naturally upon the particular use to which the finished article is to be put Simple

garden hose is often made of India-rubber or composition, but the hose intended for

fire brigade and similar important purposes must be of a much more substantial

material. The most satisfactory material is the best long flux, although cotton is also

extensively used for many types of this fabric.

4.2.3.2 Poly urethanes

Poly urethanes Is a family name given to a series of polymers that are produced

by the reaction between aromatic di-isocyanates and low molecular weight polymer

molecules

Depending on degree of formulation `the urethanes behave as thermosetting

polymer, thermoplastic polymers , elastomers .

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It has good wear resistance and resistant to oils ,greases and petrol ,Typical

application of poly urethanes include hoses, car bumpers ,shoe heel tips, hammer

heads .gears, furniture , insulation.

4.2.4 COMPRESSOR TANK:

It is a closed container designed to hold gases or liquids at a pressure

substantially different from the ambient pressure.

The pressure differential is dangerous and many fatal accidents have occurred

in the history of their development and operation. Consequently, their design,

manufacture, and operation are regulated by engineering authorities backed up by

laws. For these reasons, the definition of a pressure vessel varies from country to

country, but involves parameters such as maximum safe operating pressure and

temperature.

Compressed air tank is usually made of cast iron to with stand the pressure and

high temperature.

4.2.4.1 Cast iron:

Cast iron usually refers to gray iron, but also identifies a large group of ferrous

alloys, which solidify with a eutectic. The colour of a fractured surface can be used to

identify an alloy. White cast iron is named after its white surface when fractured, due

to its carbide impurities which allow cracks to pass straight through. Grey cast iron is

named after its grey fractured surface, which occurs because the graphitic flakes

deflect a passing crack and initiate countless new cracks as the material breaks.

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4.2.4.2 Properties:

Carbon (C) and silicon (Si) are the main alloying elements, with the amount

ranging from 2.1 to 4 wt% and 1 to 3 wt%, respectively. Iron alloys with less carbon

content are known as steel. While this technically makes these base alloys ternary Fe-

C-Si alloys, the principle of cast iron solidification is understood from the binary iron-

carbon phase diagram. Since the compositions of most cast irons are around the

eutectic point of the iron-carbon system, the melting temperatures closely correlate,

usually ranging from 1,150 to 1,200 °C (2,102 to 2,192 °F), which is about 300 °C

(572 °F) lower than the melting point of pure iron.

Cast iron tends to be brittle, except for malleable cast irons. With its relatively

low melting point, good fluidity, castability, excellent machinability, resistance to

deformation and wear resistance, cast irons have become an engineering material with

a wide range of applications and are used in pipes, machines and automotive industry

parts, such as cylinder heads (declining usage), cylinder blocks and gearbox cases

(declining usage). It is resistant to destruction and weakening by oxidization (rust).

4.2.5 TURBINE BLADES:

This is made of aluminum because of its light weight and machineability.

Aluminum Physical properties:

Density : 2.70 ×10-6 kg/mm3

Liquid density : 2.375 ×10-6 kg/mm3

Melting point : 660.32 °C, 

Boiling point : 2519 °C

Heat of fusion : 10.71 kJ·mol−1

Heat of vaporization : 294.0 kJ·mol−1

Specific heat : 24.200 J·mol−1·K−1

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4.2.6 DC GENERATOR;

In electricity generation, an electric generator is a device that converts

mechanical energy to electrical energy. The reverse conversion of electrical energy

into mechanical energy is done by a motor; motors and generators have many

similarities. A generator forces electrons in the windings to flow through the external

electrical circuit.

It is somewhat analogous to a water pump, which creates a flow of water but

does not create the water inside. The source of mechanical energy may be a

reciprocating or turbine steam engine, water falling through a turbine or waterwheel,

an internal combustion engine, a wind turbine, a hand crank, compressed air or any

other source of mechanical energy.

4.2.7 BATTERY:

In isolated systems away from the grid, batteries are used for storage of excess

solar energy converted into electrical energy. The only exceptions are isolated

sunshine load such as irrigation pumps or drinking water supplies for storage. In fact

for small units with output less than one kilowatt. Batteries seem to be the only

technically and economically available storage means.

Since both the photo-voltaic system and batteries are high in capital costs. It is

necessary that the overall system be optimized with respect to available energy and

local demand pattern. To be economically attractive the storage of solar electricity

requires a battery with a particular combination of properties:

(1) Low cost

(2) Long life

(3) High reliability

(4) High overall efficiency

(5) Low discharge

(6) Minimum maintenance

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(A) Ampere hour efficiency

(B) Watt hour efficiency

4.2.8 INVERTER:

An inverter is an electrical device that converts direct current (DC) to

alternating current (AC); the converted AC can be at any required voltage and

frequency with the use of appropriate transformers, switching, and control circuits.

Solid-state inverters have no moving parts and are used in a wide range of

applications, from small switching power supplies in computers, to large electric

utility high-voltage direct current applications that transport bulk power. Inverters are

commonly used to supply AC power from DC sources such as solar panels or

batteries.

There are two main types of inverter. The output of a modified sine wave

inverter is similar to a square wave output except that the output goes to zero volts for

a time before switching positive or negative. It is simple and low cost

(~$0.10USD/Watt) and is compatible with most electronic devices, except for

sensitive or specialized equipment, for example certain laser printers.

A pure sine wave inverter produces a nearly perfect sine wave output (<3% total

harmonic distortion) that is essentially the same as utility-supplied grid power. Thus it

is compatible with all AC electronic devices. This is the type used in grid-tie inverters.

Its design is more complex, and costs 5 or 10 times more per unit power (~$0.50 to

$1.00USD/Watt).[1] The electrical inverter is a high-power electronic oscillator. It is so

named because early mechanical AC to DC converters was made to work in reverse,

and thus was "inverted", to convert DC to AC.The inverter performs the opposite

function of a rectifier.

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4.2.9 FLORESCENT TUBE:

A fluorescent lamp or fluorescent tube is a gas-discharge lamp that uses

electricity to excite mercury vapor. The excited mercury atoms produce short-wave

ultraviolet light that then causes a phosphor to fluoresce, producing visible light. A

fluorescent lamp converts electrical power into useful light more efficiently than an

incandescent lamp.

Lower energy cost typically offsets the higher initial cost of the lamp. The lamp

fixture is more costly because it requires a ballast to regulate the current through the

lamp. While larger fluorescent lamps have been mostly used in commercial or

institutional buildings, the compact fluorescent lamp is now available in the same

popular sizes as incandescent and is used as an energy-saving alternative in homes.

4.2.10 ELECTRIC WIRES:

Electrical wiring in general refers to insulated conductors used to carry

electricity, and associated devices. This article describes general aspects of electrical

wiring as used to provide power in buildings and structures, commonly referred to as

building wiring. This article is intended to describe common features of electrical

wiring that should apply worldwide. Electric wire is usually made by copper

because of its high conductivity and ductile .

4.2.10.1 Copper:

Copper is a chemical element with the symbol Cu (from Latin: cuprum) and

atomic number 29. It is a ductile metal, with very high thermal and electrical

conductivity. Pure copper is rather soft and malleable, and a freshly exposed surface

has a reddish-orange color. It is used as a thermal conductor, an electrical conductor, a

building material, and a constituent of various metal alloys.

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Copper metal and alloys have been used for thousands of years. In the Roman

era, copper was principally mined on Cyprus, hence the origin of the name of the

metal as Cyprium, "metal of Cyprus", later shortened to Cuprum.

Copper compounds are commonly encountered as salts of Cu2+, which often

impart blue or green colors to minerals such as turquoise and have been widely used

historically as pigments. Copper metal architectural structures and statuary eventually

corrode to acquire a characteristic green patina. Copper as both metal and pigmented

salt, has a significant presence in decorative art.

Copper(II) ions (Cu2+) are soluble in water, where they function at low

concentration as bacteriostatic substances, fungicides, and wood preservatives. In

sufficient amounts, copper salts can be poisonous to higher organisms as well.

However, despite universal toxicity at high concentrations, the Cu2+ ion at lower

concentrations is an essential trace nutrient to all higher plant and animal life. In

animals, including humans, it is found widely in tissues, with concentration in liver,

muscle, and bone. It functions as a co-factor in various enzymes and in copper-based

pigments.

4.2.11 SAFETY VALVE:

A safety valve is a valve mechanism for the automatic release of a substance

from a boiler, pressure vessel, or other system when the pressure or temperature

exceeds preset limits.

It is part of a bigger set named pressure safety valves (PSV) or pressure relief

valves (PRV). The other parts of the set are named relief valves, safety relief valves,

pilot-operated relief valves, low pressure safety valves, vacuum pressure safety

valves.

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Safety valves were first used on steam boilers during the industrial revolution.

Early boilers without them were prone to accidental explosion.Vacuum safety valves

(or combined pressure / vacuum safety valves) are used to prevent a tank to collapse

when emptying it or when cold rinse water is used after hot CIP or SIP. The

calculation method is not defined in any norm when sizing a vacuum safety valve,

particularly in the hot CIP / cold water scenario, but some manufacturers [1] have

developed simulations to do so

4.2.12 BALL VALVE:

A ball valve is a valve with a spherical disc, the part of the valve which controls

the flow through it. The sphere has a hole, or port, through the middle so that when

the port is in line with both ends of the valve, flow will occur. When the valve is

closed, the hole is perpendicular to the ends of the valve, and flow is blocked. The

handle or lever will be inline with the port position letting you "see" the valve's

position. The ball valve, along with the butterfly valve and plug valve, are part of the

family of quarter turn valves.

Ball valves are durable and usually work to achieve perfect shutoff even after

years of disuse. They are therefore an excellent choice for shutoff applications (and

are often preferred to globe valves and gate valves for this purpose). They do not offer

the fine control that may be necessary in throttling applications but are sometimes

used for this purpose.

Ball valves are used extensively in industrial applications because they are very

versatile, supporting pressures up to 700 bars and temperatures up to 200°C. Sizes

typically range from 0.5 cm to 30 cm. They are easy to repair and operate. The body

of ball valves may be made of metal, plastic or metal with a ceramic center. The ball

is often chrome plated to make it more durable.A ball-check valves is a type of check

valve with a ball without a hole for a disc

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4.2.13 TYRE:

A tire (in American English and Canadian English) or tyre (in British English,

New Zealand English, Australian English and others) is a ring-shaped covering that

fits around a wheel rim to protect it and enable better vehicle performance by

providing a flexible cushion that absorbs shock while keeping the wheel in close

contact with the ground. The word itself may be derived from the word "tie," which

refers to the outer steel ring part of a wooden cart wheel that ties the wood segments

together (see Etymology below).

The fundamental materials of modern tires are synthetic rubber, natural rubber,

fabric, and wire, along with other compound chemicals. They consist of a tread and a

body. The tread provides traction while the body ensures support. Before rubber was

invented, the first versions of tires were simply bands of metal that fitted around

wooden wheels in order to prevent wear and tear.

Today, the vast majority of tires are pneumatic, comprising a doughnut-shaped

body of cords and wires encased in rubber and generally filled with compressed air to

form an inflatable cushion. Pneumatic tires are used on many types of vehicles, such

as bicycles, motorcycles, cars, trucks, earthmovers, and aircraft.

4.3 PROCESS IDENTIFICATION

4.3.1 Lathe:

A lathe may or may not have a stand (or legs), which sits on the floor and

elevates the lathe bed to a working height. Some lathes are small and sit on a

workbench or table, and do not have a stand.

Almost all lathes have a bed, which is (almost always) a horizontal beam

(although some CNC lathes have a vertical beam for a bed to ensure that swarf, or

chips, falls free of the bed). A notable exception is the Hegner VB36 Master

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Bowlturner, a woodturning lathe designed for turning large bowls, which in its basic

configuration is little more than a very large floor-standing headstock.

At one end of the bed (almost always the left, as the operator faces the lathe) is

a headstock. The headstock contains high-precision spinning bearings. Rotating within

the bearings is a horizontal axle, with an axis parallel to the bed, called the spindle.

Spindles are often hollow, and have exterior threads and/or an interior Morse taper on

the "inboard" (i.e., facing to the right / towards the bed) by which work holding

accessories may be mounted to the spindle. Spindles may also have exterior threads

and/or an interior taper at their "outboard" (i.e., facing away from the bed) end, and/or

may have a hand wheel or other accessory mechanism on their outboard end. Spindles

are powered, and impart motion to the work piece.

The spindle is driven, either by foot power from a treadle and flywheel or by a

belt or gear drive to a power source. In most modern lathes this power source is an

integral electric motor, often either in the headstock, to the left of the headstock, or

beneath the headstock, concealed in the stand.

In addition to the spindle and its bearings, the headstock often contains parts to

convert the motor speed into various spindle speeds. Various types of speed-changing

mechanism achieve this, from a cone pulley or step pulley, to a cone pulley with back

gear (which is essentially a low range, similar in net effect to the two-speed rear of a

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truck), to an entire gear train similar to that of a manual-shift auto transmission. Some

motors have electronic rheostat-type speed controls, which obviates cone pulleys or

gears.

The counterpoint to the headstock is the tailstock, sometimes referred to as the

loose head, as it can be positioned at any convenient point on the bed, by undoing a

locking nut, sliding it to the required area, and then relocking it. The tailstock contains

a barrel which does not rotate, but can slide in and out parallel to the axis of the bed,

and directly in line with the headstock spindle. The barrel is hollow, and usually

contains a taper to facilitate the gripping of various type of tooling. Its most common

uses are to hold a hardened steel centre, which is used to support long thin shafts

while turning, or to hold drill bits for drilling axial holes in the work piece. Many

other uses are possible.

Metalworking lathes have a carriage (comprising a saddle and apron) topped

with a cross-slide, which is a flat piece that sits crosswise on the bed, and can be

cranked at right angles to the bed. Sitting atop the cross slide is usually another slide

called a compound rest, which provides 2 additional axes of motion, rotary and linear.

Atop that sits a tool post, which holds a cutting tool which removes material from the

work piece. There may or may not be a lead screw, which moves the cross-slide along

the bed.

Woodturning and metal spinning lathes do not have cross-slides, but rather have

banjos, which are flat pieces that sit crosswise on the bed. The position of a banjo can

be adjusted by hand; no gearing is involved. Ascending vertically from the banjo is a

toolpost, at the top of which is a horizontal tool rest. In woodturning, hand tools are

braced against the tool rest and levered into the work piece. In metal spinning, the

further pin ascends vertically from the tool rest, and serves as a fulcrum against which

tools may be levered into the work piece.

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4.3.2 Boring:

In machining, boring is the process of enlarging a hole that has already been

drilled (or cast), by means of a single-point cutting tool (or of a boring head

containing several such tools), for example as in boring a cannon barrel. Boring is

used to achieve greater accuracy of the diameter of a hole, and can be used to cut a

tapered hole.

Fig

There are various types of boring. The boring bar may be supported on both

ends (which only works if the existing hole is a through hole), or it may be supported

at one end. Lineboring (line boring, line-boring) implies the former. Backboring

(back boring, back-boring) is the process of reaching through an existing hole and

then boring on the "back" side of the workpiece (relative to the machine headstock).

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4.3.3 Welding:

Welding is a fabrication or sculptural process that joins materials, usually

metals or thermoplastics, by causing coalescence. This is often done by melting the

work pieces and adding a filler material to form a pool of molten material (the weld

pool) that cools to become a strong joint, with pressure sometimes used in conjunction

with heat, or by itself, to produce the weld. This is in contrast with soldering and

brazing, which involve melting a lower-melting-point material between the work

pieces to form a bond between them, without melting the work pieces.

Fig

Many different energy sources can be used for welding, including a gas flame,

an electric arc, a laser, an electron beam, friction, and ultrasound. While often an

industrial process, welding can be done in many different environments, including

open air, under water and in outer space. Regardless of location, welding remains

dangerous, and precautions are taken to avoid burns, electric shock, eye damage,

poisonous fumes, and overexposure to ultraviolet light.

Until the end of the 19th century, the only welding process was forge welding,

which blacksmiths had used for centuries to join iron and steel by heating and

hammering them. Arc welding and oxyfuel welding were among the first processes to

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develop late in the century, and resistance welding followed soon after. Welding

technology advanced quickly during the early 20th century as World War I and World

War II drove the demand for reliable and inexpensive joining methods.

Following the wars, several modern welding techniques were developed,

including manual methods like shielded metal arc welding, now one of the most

popular welding methods, as well as semi-automatic and automatic processes such as

gas metal arc welding, submerged arc welding, flux-cored arc welding and electro slag

welding. Developments continued with the invention of laser beam welding and

electron beam welding in the latter half of the century. Today, the science continues to

advance. Robot welding is becoming more commonplace in industrial settings, and

researchers continue to develop new welding methods and gain greater understanding

of weld quality and properties.

SPECIFICATOIN

1. SINGLE ACTING PNEUMATIC CYLINDER Technical Data Stroke length : Cylinder stoker length 170 mm Quantity : 1 Seals : Nitride (Buna-N) Elastomer End cones : Cast iron Piston : EN – 8 Media : Air Temperature : 0-80 º C Pressure Range : 8 N/m²

2. NON-RETURN VALVE:- Quantity : 1 Media : Air Temperature : 0-80 º C Pressure Range : 0-8 N/m² Size : ¼”  

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QUICK EXHAUST VALVE:-  Quantity : 2 Media : Air Temperature : 0-80 º C Pressure Range : 0-8 N/m² Size : ¼”

Connectors Max working pressure : 10 x 10 ⁵ N/m² Temperature : 0-100 º C Fluid media : Air Material : Brass  

5. Hoses Max pressure : 10 x 10 ⁵ N/m² Outer diameter : 6 mm = 6 x 10 ˉ ³m Inner diameter : 3.5 mm = 3.5 x 10 ˉ ³m

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DESIGN CALCULATION:

Force acting on the rod (P) = Pressure x Area = p x (Πd² / 4) = 6 x {( Π x 4² ) / 4 }

P = 733.6 N   Design Stress (σy) = σy / F0S

= 36 / 2 = 18 N/mm² = P / (Π d² / 4)

∴ d = √ 4 p / Π [ σy ] = √ 4 x 75.36 / {Π x 18}

= √ 5.33 = 2.3 mm

∴ Minimum diameter of rod required for the load (d) = 2.3 mm We assume diameter of the rod (d) = 15 mm

Design of cylinder thickness:   Material used = Cast iron Assuming internal diameter of the cylinder = 40 mm Ultimate tensile stress = 250 N/mm² Working Stress = Ultimate tensile stress /factor of safety Assuming factor of safety = 4

Working stress ( ft ) = 2500 / 4 = 62.5 N/mm²

According to ‘LAMES EQUATION’  

Minimum thickness of cylinder ( t ) = ri {√ (ft + p) / (ft – p ) -1 } Where,

ri = inner radius of cylinder in mm. ft = Working stress (N/mm²) p = Working pressure in N/mm²

∴ Substituting values we get, t = 20 {√ (625 + 6) / ( 625 – 6) -1}

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t = 0.019 cm = 0.19 mm   We assume thickness of cylinder = 2.5 mm Inner diameter of barrel = 40 mm Outer diameter of barrel = 40 + 2t   = 40 + ( 2 x 2.5 ) = 45 mm

Design of Piston rod:

Diameter of Piston Rod: Force of piston Rod (P) = Pressure x area = p x Π/4 (d²)

= 6 x (Π / 4) x (4)² = 733.6 N

Also, force on piston rod (P) = (Π/4) (dp)² x ft P = (Π/4) x (dp)² x 625 73.36 = (Π/4) x (dp)² x 625 ∴ dp² = 73.36 x (4/Π) x (1/625)

= 0.15 dp = 0.38 cm = 3.8 mm

By standardizing dp = 15 mm

Length of piston rod:

Approach stroke = 160 mm Length of threads = 2 x 20 = 40mm Extra length due to front cover = 12 mm Extra length of accommodate head = 20 mm Total length of the piston rod = 160 + 40 + 12 + 20 = 232 mm

By standardizing, length of the piston rod = 230 mm

COMPRESSED AIR PRODUCTION:-   Diameter of the cylinder = 40 mm = 4 cm Stroke length = 170 mm Pressure = force / area

= 100kg / (3.14 x 4*4/4) = 100/12.56 =0.7808 N/mm2

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SCHEMATIC LAYOUT

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CHAPTER

APPLICATION Compressed air produced by this method can be used tyre inflation.

It can used for air braking system.

Automatic door opening and closing can be achieved using compressed air

produced by this method.

It can be used for operating wiper motor.

Turbo charger can be operated by compressed air.

Pneumatic jack can be operated by compressed air.

Compressed air can be used for dust removal.

Alternative energy source for air conditioning system.

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CONCLUSION

This project work is providing us an excellent opportunity and experience, to

use our limited knowledge. We are gaining a lot of practical knowledge regarding,

planning, purchasing, assembling and machining while doing this project work. We

feel that the project work is a good solution to bridge the gates between institution and

industries.

In concluding the words of our project, since the compressed air production

using vehicle suspensor get its energy requirements from the Non-renewable source of

energy. There is no need of power from the mains and there is less pollution in this

source of energy. It is very useful to the places all roads. It is able to extend this

project by using same arrangement and construct in the steps so that increase the air

production rate by fixing school and colleges, etc

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REFERENCES

1. Åke Karlsson, Gränges Technology Service (GTC), Finspång and by Skanaluminium, Oslo ‘ A Compressed Air Tank for a Lorry’

2. Krähenbühl. D , C Zwyssig, H. Hörler and J. W. Kolar , Power Electronic Systems Laboratory ‘Design Considerations and Experimental Results of a 60 W Compressed-Air-to-Electric-Power System’

3. Marc-Michel Bodet  Ludger Frilling  Frank Meissner NEW YORK, NY US

‘Compressor unit for a vehicle air suspension system’

4. Michel Rigal Gilles Hebrard WASHINGTON, DC US ‘Reciprocating-Piston Compressor Having Non-Contact Gap Seal’

BIBLIOGRAPHY

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1. Donald. L. Anglin, “Automobile Engineering”

2. G.B.S. Narang, “Automobile Engineering”, Khanna Publishers, Delhi, 1991, pp

671.

3. Majumdhar , ‘Pneumatic System’. New Age India International (P) Ltd

Publishers, 1997.

4. Stroll & Bernaud , ‘Pneumatic Control System’ Tata Mc Graw Hill

Publications, 1999.

5. William H. Crowse, “Automobile Engineering”.

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