“design and fabrication of electronic chassis adjustment

VISVESVARAYA TECHNOLOGICAL UNIVERSITY Jnana Sangama, Belgaum, Karnataka-590 014

A PROJECT REPORT

ON

“Design and Fabrication of Electronic Chassis Adjustment System (ECAS) Using Pneumatic

System” Project Report submitted in partial fulfilment of the requirement for the

award of the degree of

BACHELORS OF ENGINEERING

IN

MECHANICAL ENGINEERING

Submitted by

Abhinav Shankar 1NH18ME004

Abraham Gibi John 1NH18ME007

Ashiq Abraham Varghese 1NH18ME022

Ashish Mathew 1NH18ME023

Under the guidance of

Dr. Sudarshan T.A Senior Assistant Professor

Department Of Mechanical Engineering

New Horizon College of Engineering

NEW HORIZON COLLEGE OF ENGINEERING DEPARTMENT OF MECHANICAL ENGINEERING

BANGALORE-560 103

2021-2022

ACKNOWLEDGEMENT

We thank the Lord Almighty for showering His blessings on us.

It is indeed a great pleasure to recall the people who have helped us in carrying out

this project. Naming all the people who have helped us in achieving this goal would be

impossible, yet we attempt to thank a selected few who have helped use in diverse ways.

We would like to express our heartfelt thanks to Dr. Mohan Manghnani, Chairman,

NHCE for providing all the facilities throughout.

We wish to express our sincere gratitude to Dr. Manjunatha, Principal, NHCE,

Bangalore, for providing us with facilities to carry out this project.

We wish to express our sincere gratitude to Dr. Shridhar Kurse, Prof. & HOD -

Mechanical Engineering, New Horizon College of Engineering for his constant

encouragement and cooperation.

We wish to express our sincere gratitude to our teacher and guide Dr. Sudarshan T.A,

Senior Assistant Professor, Department of Mechanical Engineering, New Horizon College of

Engineering, for his valuable suggestions, guidance, care & attention shown during the

planning, conduction stages of this project work.

We express our sincere thanks to project coordinators, all the staff members and

non-teaching staff of Department of Mechanical Engineering, New Horizon College of

Engineering, for the kind cooperation extended by them.

We thank our parents for their support and encouragement throughout the course of

our studies.

DECLARATION

CONTENTS

1. Chapter 1 - Introduction 2

2. Chapter 2 - Literature Review

2.1. Journal 1 2.2. Journal 2 2.3. Journal 3 2.4. Journal 4 2.5. Journal 5

3 3 4 4 5

3. Chapter 3 - Problem Identification 6

4. Chapter 4 - Objectives of the Project 7

5. Chapter 5 - Working Mechanism 8

6. Chapter 6 - Experimental Setup and Components

6.1. Required Electronic Hardware

6.1.1. Arduino Uno 6.1.2. Ultrasonic Sensor 6.1.3. IR Sensor 6.1.4. Relay 6.1.5. Double Acting Cylinder 6.1.6. Solenoid 6.1.7. Jumper Wires 6.1.8. Collar and PU Connector 6.1.9. Voltage Regulator 6.1.10. 12v Lead Acid Battery 6.1.11. 12V DC Motor

6.2. List of Material

6.3. Material Cost 6.4. Advantages 6.5. Applications

12

13 14 15 16 18 19 20 20 21 22 23

24

24 25 25

7. Results and Discussions

7.1. Catia Design 7.2. Catia Drafting 7.3. Block Diagram 7.4. Flow Chart 7.5. Coding ( Arduino IDE ) 7.6. Calculations

26 28 29 30 31 33

8. Chapter – Conclusion and Future Scope

8.1. Conclusion 8.2. Future Scope

35 35

9. References 36

TABLE OF FIGURES

Figure No Figure Name Page No

5.1 Lean, Load and Effect Diagram 8

5.2 Chassis Lift Setup 9

6.1 Experimental Setup 12

6.2 Arduino Uno Board 13

6.3 Architecture of IR Sensor 15

6.4 Relay 16

6.5 Relay Circuit Diagram 16

6.6 Relay Pin Configuration and Logic Diagram 17

6.7 Double Acting Pneumatic Cylinder 18

6.8 Solenoid 19

6.9 Jumper Wires 20

6.10 Hose Collar 20

6.11 LM2596S Voltage Regulator 21

6.12 Lead Acid 12v Rechargeable Battery 22

6.13 DC Motor 23

7.1 Isometric View Body 26

7.2 Side View 26

7.3 Bottom View 27

7.4 Front View 27

7.5 Top View 27

7.6 Catia Drafting 28

7.7 Block Diagram 29

7.8 Flow Chart 30

LIST OF TABLES

Table No Table Name Page No

6.1 List of Materials 24

6.2 Material Costs 24

Design and Fabrication of Electronic Chassis Adjustment System using Pneumatic system

Department of mechanical Engineering, NHCE 2021-22 1

ABSTRACT

The centre of gravity of the vehicle is one of the many factors that affect how a vehicle handle. We must keep the centre of gravity as low as we can for optimal vehicle handling. While it is always kept low for sports cars, it compromises the ground clearance of passenger vehicles. The system is designed to acquire the necessary suspension settings. The designers desire to keep fixed ground clearance. A sedan or hatchback, on the other hand, must occasionally go over uneven terrain due to their set lower ground clearance, which tends to cause dents on the car's bottom. For the vehicle to operate at its best in both scenarios, an adjustable ground clearance system is required. The pneumatic lifting technique is described in this paper as a way to retain stability at high speeds on smooth roads while providing more ground clearance on uneven roads or when driving over breakers.

The methods created to identify potholes and speed bumps on the roadways are also discussed in this research. In order to prevent accidents and car damage, this project also gives the GPS coordinates to the appropriate authorities and periodically updates drivers on the road conditions. Here, an ultrasonic sensor is utilized to locate the potholes and humps as well as to determine the height of the humps, the depth of the potholes, and their distance from the vehicles. Pothole depth, hump height, and target separation from the vehicle are among the sensed data. The vehicles use this measured information as a useful resource to notify the drivers, advise them to take safety precautions, prevent accidents, and submit the data to the appropriate authorities to address any issues. For increased vehicle safety and maneuverability, some implementations of a rapid-response active suspension system manage suspension force and position. The system may communicate with multiple sensors that identify safety-critical vehicle conditions and modify each wheel's suspension to enhance safety. The active suspension controller may be alerted to a collision by pre-crash and collision sensors, and the stance may be changed to increase occupant safety during an impact while still having active control over the wheels. Wheel forces may also be regulated to enhance the performance of traction- improving car safety systems like ABS and ESP. Additionally, the active suspension system and other car safety systems may exchange information in both directions, allowing each system to react to data sent to the other.



CHAPTER – 1

INTRODUCTION

People are frequently connected by roads in a nation like India. Despite the fact that most roads are well paved, others are not. People can frequently be observed denouncing the government for the unfavorable conditions, even in many major cities. Road is straight when specific conditions are met; else, irregularities are discovered. While driving a car on a highway or in a city, there are still certain obstacles. Off-road vehicles cannot travel at high speeds with their conventional ground clearance because of the obstructions in cities, whereas on-road vehicles can go across tough terrain with their lower ground clearance. Building one system with adjustable ground clearance is required to achieve good performance at both high and low speeds. This can be done by adjusting the suspension height, which will allow the chassis height to be modified according to the speed and condition of the roads. When building an automobile for good stability and road holding ability, suspension systems are crucial.

With the aim of reducing complexity and cost while enhancing ride, handling, and

performance, we can use a combination of active and passive suspension systems to solve

this issue.

In this study, several aspects of the ground clearance, suspension system, and its

control are explored. This provides information on the effects of vehicle attributes

including ride control, height control, roll control, and road holding on performance. The

height of the vehicle body (sprung mass) above the ground is referred to as ground

clearance. It is a crucial component of an off-road vehicle. Because of the mechanical down

force that acts on tyres for a given car’s weight, the grip of tyres changes constantly while

the vehicle is in motion. The centre of gravity is where a vehicle's entire weight is

concentrated. The centre of gravity is found close to the ground when the ground clearance

is reduced. This improves the vehicle's performance by reducing weight transfer during

cornering, accelerating, and braking. Additionally, we can increase high speed stability by

lowering the front end and increasing the back end. Since the majority of the vehicle’s

operating parameters are influenced by the centre of gravity. Depending on the state of

the road, we require a centre of gravity that is both high and low. For adjusting ground

clearance, we created a straightforward pneumatic connection device. An active

suspension and a passive suspension that are connected in series allows for adjustment.

The passive suspension comes before the active suspension. This mechanism allows us to

adjust the vehicle’s ground clearance by up to 200mm. Pneumatic cylinders are mechanical

devices that generate force in a reciprocating linear motion using the power of compressed

gas. A piston is propelled in the desired direction, much like in hydraulic cylinders. As a

result, the intended direction is lifted. When necessary, an air compressor is used to

provide a pneumatic lift that raises the chassis above the ground; if not, it lowers the

chassis to its standard position by serving as an active suspension system.



CHAPTER - 2 LITERATURE REVIEW

2.1 Journal 1: A new control strategy for active suspension using modified

fuzzy and PID controllers.

Mohammad H. AbuShaban, Mahir B. Sabra, Iyad A. Abuhadrous ; The 4th International Engineering Conference- Towards Engineering of 21st Century, October 2012

The journal describes a controlled technique to use an electro-hydraulic actuator to

control the suspension system. Low frequency active suspension is used to replace the

passive suspension. The quarter-car model was tested at various speeds and on various

road surfaces for the effects of rolling, cornering, and pitching. Better road holding and

vehicle stability result from a 60 percent reduction in body acceleration. Active suspensions

can be divided into two categories: low bandwidth suspensions and high bandwidth

suspensions. Because they perform well under the harshest driving conditions, non-linear

controllers are better able to manage high bandwidth active suspension. Researchers

provide a new PID with a fuzzy switch to the linear controller hyperactive suspension of

limited bandwidth, improving suspension performance.

2.2 Journal 2: Advance the stability of the vehicle by using the pneumatic

suspension system

Tuan Anh Nguyen; Lat. Am. j. solids struct. vol.18 no.7 Rio de Janeiro 2021 Epub Nov 01, 2021

The suspension system's performance affects a vehicle's stability and comfort. The

suspension system's stiffness needs to be adjusted flexibly in order to improve the

smoothness and comfort of the ride for the passengers. These requirements can be

partially satisfied by the traditional pneumatic suspension method. The modification is

minor, though. A model of the pneumatic suspension system is presented in this study. The

introduction and analysis of the pneumatic suspension system's properties. The rigidity and

height of the vehicle are directly impacted by the pneumatic suspension system.



2.3 Journal 3: Modelling and analysis of vehicle crash system integrated

with different VDCS under high-speed impacts

Mustafa Elkady, Ahmed Elmarakbi; Central European Journal of Engineering, September

2012

Active vehicle dynamics control systems improve how a car behaves in high-speed

collisions. Vehicle dynamics and vehicle collision structural dynamics are also investigated

in this model. To make sure that the modelling of the crumble zone and the dynamic

reactions are accurate, the suggested model's car crash structure is validated. To examine

the resilience of the control system and its impact on the vehicle crash characteristics at

low and high speeds with full and offset collision situations, five different speeds were

chosen. From this analysis, the control motor's accelerations at high-speed collisions and

the movement of the vehicle's pitch and yaw angels are determined.

2.4 Journal 4: Axiomatic design of customizable automotive suspension Hrishikesh V Deo, Nam P Suh; Proceedings of ICAD2004 The Third International

Conference on Axiomatic Design; ICAD-2004-38

This paper explores the relationship between a vehicle's centre of gravity and its

comfort and handling capabilities. Additionally, it discussed the requirements for

dampening under various circumstances. They created a suspension system whose height

and stiffness could change along with the speed, changing the ride height. The investigation

utilized a short-long-arm suspension system, which is frequently employed for the front

wheels' suspension.

Making the lower spring pivot adjustable along the lower control arm will allow you

to adjust the height and stiffness.

Electric motors are utilized to operate the actuators in order to move the pivot

point and bring it to the desired position. Observed flaws include the absence of quick

reaction and sluggish response. Adaptive control and adaptive changing heights were also

proposed as ways to get around active and semi-active suspension systems, as well as their

imitations.

https://www.researchgate.net/publication/257909753_Modelling_and_analysis_of_vehicle_crash_system_integrated_with_different_VDCS_under_high_speed_impacts

https://www.researchgate.net/publication/257909753_Modelling_and_analysis_of_vehicle_crash_system_integrated_with_different_VDCS_under_high_speed_impacts

https://link.springer.com/journal/13531



2.5 Journal 5: The Pneumatic Actuators as Vertical Dynamic Load

Simulators on Medium Weighted Wheel Suspension Mechanism Simon Ka’ka, Syukri Himran, Ilyas Renreng, Onny Sutresman

International Conference on Nuclear Technologies and Sciences (ICoNETS 2017)

The majority of road damage can be attributed to dynamic loads of vehicles, which

change depending on the kind of vehicle passing through. This study tries to determine the

vehicle's true vertical dynamic load on the road construction using the wheel suspension

system. Directly loading the spring and shock absorber mounted on the vehicle's wheels

are pneumatic cylinders powered by pressurized air. The amount of compressed air that

enters the pneumatic cylinder chamber and pushes the piston and connecting rods

determines how much load variation occurs in vehicles classified as medium weight. While

accounting for the spring stiffness constant and the fluid or damper gas coefficient, the

displacement that results from compression on the spring and shock absorber is inserted

into the equation of vehicle dynamic load. The findings demonstrate that the amount of

vertical dynamic load carried by the vehicle above the road construction is significantly

influenced by the size of the displacement when the compression force acts. The reduction

in the capacity of the road to carry the load is also impacted by the existence of dynamic

loads of cars that change and repeat.



CHAPTER - 3

PROBLEM IDENTIFICATION

This project addresses a solution for the issue of increasing ground clearance when faced with large potholes and unscientific speed humps that generally lead to damage on the underside of a vehicle.



CHAPTER – 4

OBJECTIVES OF THE PROJECT

• To detect speed humps and potholes efficiently and effectively on the road.

• Increase the ride height of the vehicle on detecting of imperfection to prevent body damage to the vehicle

• To adjust the ride height to optimum level to increase efficiency and cabin comfort.



CHAPTER – 5

WORKING MECHANISM

Fig 5.1 Body Lean, Load and Effect Diagram

Similar to hydraulic systems, pneumatic systems use compressed air instead of hydraulic

fluid.

A pneumatic system is one that transmits and regulates energy using compressed air.

Numerous industries make substantial use of pneumatic systems. The majority of

pneumatic systems require a steady flow of compressed air to function. An air compressor

provides this. Air from the atmosphere is drawn in by the compressor and stored in a

receiver, a high-pressure container. The system is then supplied with this compressed air

via a network of pipelines and valves.

The pneumatic system is what powers the pneumatic bumper system. The barrier

is found using an ultrasonic sensor. the command that controls the solenoid valve and is

sent to the microcontroller. The pneumatic actuator receives compressed air through a

compressor. Compressed air is supplied through the solenoid valve to control the solenoid

valve's state, which activates the pneumatic actuator. The pneumatic actuator's piston will

move in an upward direction. The actuator will return to its initial position after the

obstruction has been removed.



Fig 5.2 Chassis Lift Setup

By simply pressing the button that activates the engine by connecting it to the

battery, a person driving a car on a smooth road can choose to increase the ground

clearance when he or she observes a rough, uneven road or rugged terrain in front of the

vehicle. By pressing a different button that releases high-pressured air into the air and

causes all of the raised pistons in the pneumatic cylinders to fall to the position of the inner

dead centre, the driver of the vehicle can lower the chassis height after the difficult terrain

is finished. The outlet valve of pneumatic cylinders is closed when the pushed button is

released. Again, the driver can use the car's conventional ground clearance to maintain a

proper centre of gravity and maximize acceleration.

The pneumatic lift system used in the prototype to raise the ground clearance is

effective. With a 5bar compressor, it can lift the weight of a chassis up to 30 to 40 kg, which

is sufficient for smaller-scale tasks. After receiving input from the controller, the

mechanisms can lift the chassis in no more than five seconds, and they can then maintain

a fixed higher ground clearance for however long is necessary to preserve the prototype

chassis. Later, the chassis can be lowered using a controller to achieve a fixed lower ground

clearance in 5 seconds. Additionally, performance can be improved. You can group the

outcomes into:

• The mechanism typically needs 2 seconds to change the vehicle's ground clearance.

• Along the barriers, the vehicle's ground clearance is boosted by 3 cm. Damage to



the car's chassis is avoided.

• With a 350-psi compressor, the system can support a weight of 3 to 4 kg.

• The project functions well as a prototype, but there is a potential that the outcome

will change when the pneumatic system is used in real-world settings.

However, performance can be improved with good design and mechanism, accurate

measurement, and real-time application. Because of this automatic braking system, each

component's function is successfully carried out, as is the purpose of the entire system.

Once the safety distance has been established and an impediment has been recognized,

the vehicle system is shut off. This prototype's ultrasonic sensor has a ranging accuracy of

around 2 cm to 1 m and operates efficiently within the allowed range.

Automatic Ground Clearance: -

Chassis, D.C. motors, ultrasonic sensors, alarms, indicators, and batteries make up the

majority of the components. These parts are utilized in the Automatic Ground Clearance

Adjustment System's design and construction. The system's operational mechanism is

• Under the bumper and in strategic locations on the chassis are Ultra Sonic Sensors.

The clearance height of the vehicle is continuously detected by ultrasonic sensors.

• The Arduino board circuit receives signals from the ultrasonic sensors, which are

used to identify impediments like speed bumps and slopes.

• The Arduino board supplies power to the solenoid valve using a relay switch. The

pneumatic cylinder raises the chassis, increasing the clearance from the ground.

• The solenoid valve operates and lowers the chassis to maintain the standard ground clearance when the ultrasonic sensors detect no impediments. This is done by

sending signals to the Arduino board. operative mechanism the propensity of a

force to rotate an item about an axis, fulcrum, or pivot is known as torque, moment,

or moment of force. A torque can be thought of as an object's twist, just as a force

is a push or a pull.

Result

The pneumatic lift system used in the prototype to raise the ground clearance is

effective. With a 5bar compressor, it can lift the weight of a chassis up to 30 to 40 kg, which

is sufficient for smaller-scale tasks. After receiving input from the controller, the

mechanisms can lift the chassis in no more than five seconds, and they can then maintain

a fixed higher ground clearance for however long is necessary to preserve the prototype

chassis. Later, the chassis can be lowered using a controller to achieve a fixed lower ground

clearance in 5 seconds. Additionally, performance can be improved. You can group the



outcomes into:

• The mechanism typically needs 5 seconds to change the vehicle's ground clearance.

• Along the barriers, the vehicle's ground clearance is boosted by 3 cm. Damage to

the car's chassis is avoided

• With a 350-psi compressor, the system can support a weight of 3 to 4 kg.

• The project functions well as a prototype, but there is a potential that the outcome

will change when the pneumatic system is used in real-world settings.

However, performance can be improved with good design and mechanism, accurate

measurement, and real-time application. Because of this automatic braking system, each

component's function is successfully carried out, as is the purpose of the entire system.

Once the safety distance has been established and an impediment has been recognized,

the vehicle system is shut off. This prototype's ultrasonic sensor has a ranging accuracy of

around 2 cm to 1 m and performs well within the allowed range.

Final Project Overview With the help of a battery connection and a DC gear motor

and servomotor controlling the braking system, we tested the project's functionality. This

method is environmentally beneficial, and it aims to lessen collisions when driving in

hazardous situations. By positioning several things in front of the system as barriers, we

have tested its functionality. When the impediment was positioned at different distances

from the vehicle, the system reacted by lowering its speed. Additionally, in restricted

places, the system immediately shut down. It provided extremely accurate measurement

within the range of values that were interpreted.



CHAPTER – 6

EXPERIMENTAL SETUP AND COMPONENTS

Fig 6.1 Experimental Setup



6.1 Required electronic hardware:

6.1.1 Arduino UNO

A platform, user group, and open-source hardware and software company called

Arduino creates and produces digital devices and microcontroller kits for the creation of

interactive objects that can recognize and manipulate objects in the physical environment.

The project's outputs, including the open-source software and hardware used to create

Arduino boards, are made available to everyone under the GNU General Public License

(GPL). There are pre-assembled and DIY kits for microcontrollers on the market. In Arduino

panel models, several microprocessors and controllers are employed. Numerous digital

and analogue components on the board can be connected to additional circuits. A system

communication interface and several USB variations for downloading software from a

computer are both present on the board.

• Technical Specifications

Fig 6.2 Arduino Uno Board

• Microcontroller ATMEGA328P

• Digital I/o pins 14 (OF WHICH 6 PROVIDE PWM OUTPUT)

• Operating voltage 5V

http://www.atmel.com/Images/Atmel-42735-8-bit-AVR-Microcontroller-ATmega328-328P_Datasheet.pdf



• Dc current 20 MA

• Sram 2 KB (ATMEGA328P)

• Dc current (3.3v) 50 MA

• Clock speed 16 MHZ

• Analog input pins 6

• Length 68.6 MM

6.1.2 Ultrasonic Sensor These sensors are designed to meet the typical requirements of the automotive industry.

The measuring distance varies from 0.1 to 0.3 m and has a standard uncertainty of 1 mm

over a temperature range of 0 ° C to 40 ° C. A wide temperature range is possible, but

distances of up to 1 m can be measured and there is great uncertainty.

The distance from the ground of a point of a vehicle body is computed as

Were

time of flight of an ultrasonic pulse, i.e., the time the pulse takes to cover the

distance;

constant close to 0.5, which depends on the sensor geometry

velocity of sound in air.

Ultrasonic pulses are generated by a piezoelectric transducer, and the echoes reflected

from the ground are obtained from another piezoelectric transducer. The two

transducers are mounted close to each other to form the probe head. The percentage of

uncertainty due to the constant can be slightly reduced by calibrating the sensor after

setting the measuring head. To measure distances in the range of 0.1 m to 0.3 m, you

need to measure the flight time in the range of 0.5 to 2 ms. The required distance of 1

mm can be achieved by measuring the flight time with a standard uncertainty of 2.5

seconds, measuring the temperature with a standard uncertainty of 1 C and avoiding the

use of a humidity sensor. Ultrasonic signals in the range of 30 kHz to 5 MHz can be used

to generate pulses. Higher frequencies represent shorter wavelengths and therefore

better resolution, which may be acceptable, but the attenuation of airborne sound

increases dramatically as the frequency increases. High frequencies also require both

expensive and high-speed electronic converters, so low frequencies can be avoided.

Available cost adjustments. Low frequencies have the advantage of fewer scattering

problems and can be obtained with cheap transducers, but because the wavelengths in

the air are a few millimeters, special care must be taken to obtain the measurement

uncertainty below the wavelength.



6.1.3 IR Sensor:

An infrared (IR) sensor is a sort of electrical apparatus that locates and keeps track

of infrared radiation in the surroundings. Astronomer William Hurchel made the infrared

discovery around 1800. He measured the temperature of each colour of light and found

that it was followed by the red light in having the highest temperature. Active and passive

infrared sensors are the two categories under which they fall. Infrared radiation is

produced and detected by active infrared sensors. An active infrared sensor is produced by

combining the LED (LED) and receiver. An infrared LED on the device lights when it

approaches the sensor, signaling its presence to the receiver. Active infrared sensors are

widely used as proximity sensors in interference detection systems.

Fig 6.3: Architecture of IR Sensor


• Voltage is 3.3v to 5v

• Distance: 0.5 m

• Microphone Sensitivity (1kHz): 52 to 48 dB

• PCB Size: 3.5cm * 1.6cm

• Easy to use with Microcontrollers

• Operating current: 4-5 mA



6.1.4 Relay

Relays are switches that are controlled via circuits. The device consists of a set of

operational communication terminals and an array of input terminals for one or more

control signals. An infinite number of contacts can be set up on a switch in any

arrangement, including separating contacts, setting up contacts, and combinations of the

two. Relays are used to independently regulate many low-power signals or to control

numerous circuits with a single low-power signal. Relays were initially used in long-distance

telegraphic circuits as signal amplifiers to carry messages from one circuit to another. In

telephone exchanges and early computers, relays were frequently used to carry out logical

processes.

Fig 6.4 Relay

How Relay Works?

Fig 6.5 Relay Circuit Diagram



Relay driver ULN 20003

Fig 6.6 Relay Pin Configuration and Logic Diagram

Why Relay Driver?

• ULN2003 IC safely operates the relay.

• Integrated clamping diodes shield the microprocessor from relay kickback.

• Has seven open collector Darlington pairs with common emitters, each of which

has a high current Darlington array.



6.1.5 Double Acting cylinders:

Pneumatic cylinders are mechanical devices that use compressed air to move a load

in a linear motion. They are also known as air cylinders or actuators. A piston and rod

moving inside of a closed cylinder, where the piston accomplishes the desired movement,

makes up the most typical type of pneumatic actuator. Pneumatic systems use air as the

energy source to function and finish a certain task, in this case, extending and retracting

the piston inside a cylinder.

Fig 6.7 Double Acting Pneumatic Cylinder

Technical Data

Stroke length : Cylinder stoker length 160 mm = 0.16 m 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



6.1.6 Solenoid

Single Acting Solenoid Valve, 5/2 One of the crucial components of a pneumatic

system is the directional valve. This valve, also referred to as a DCV, is used to regulate the

direction of air flow in a pneumatic system. By shifting the location of its internal movable

components, the directional valve does this. This valve was chosen to operate quickly, to

require less manual work, and to convert the machine into an automatic machine by

employing a solenoid valve.

A solenoid is an electrical device that uses electricity to create force and motion in

a straight line. Additionally, these are utilized to run a mechanical process that controls the

valve mechanism Solenoids come in push or pull varieties. In a push type solenoid, the

plunger is pushed when the solenoid is electrically energized. In a pull type solenoid, the

plunger is pulled when the solenoid is energized.

Fig 6.8 Solenoid



6.1.7 Jumper Wires:

Typically used to connect the elements of a breadboard or other prototype or test

circuit to internal or external machinery or components, conductive wire is a seamless

bundle of wires or cables with connectors or pins at each end. The "end connectors" are

used to connect individual jumper wires by placing them in the test platform, print board

header connections, or breadboard slots.

Fig 6.9 Jumper Wires

6.1.8 COLLAR AND PU CONNECTOR: -

There are two different types of connectors used in our pneumatic system: the hose connector and the reducer. An adapter (connection), hose nipple, and cap nut often make up hose connectors. Brass, aluminum, or hardened steel are the materials used to make these connectors. Reducers are used to join two pipes or hoses of various sizes together. They could be fitted in a straight, tee, "V," or different ways. Gunmetal or other materials, such as hardened steel, are used to make these reducers.

Polyurethane hoses are employed in this pneumatic system. These hoses can withstand pressures up to 10 kg/cm2 maximum.

Fig 6.10 Hose Collar



6.1.9 Voltage Regulator:

A voltage regulator is a device that maintains a steady voltage on its own. Negative

feedback or simple redirect designs can be used in voltage regulators. It is possible to

employ electromechanical mechanisms or electrical components. It can be used to manage

one or more AC or DC voltages, depending on the design. Electronic voltage regulators

manage the DC voltage utilized by other device components such as the CPU and the

computer's power sources. Voltage regulators regulate the output of vehicle generators

and power plant generators. Voltage regulators can be installed at substations or along a

distribution system's distribution lines. This guarantees that all users, regardless of energy

consumption, receive a steady voltage.

Fig. 6.11 LM2596S voltage regulator


• 3-A output load current

• 0.3-V, 5-V, 12-V, and adjustable output versions

• Available in TO-220 and TO-263 packages

• Input voltage is 40 V

• 150-kHz frequency



6.1.10 12v Lead Acid Battery:

Lead-acid batteries, is a rechargeable battery. It's the world's first rechargeable battery.

The power density of lead-acid batteries is lower than that of current rechargeable

batteries. Cells, on the other hand, have a high power-to-weight ratio due to their capacity

to transmit powerful currents from the outside environment. These characteristics make

them appealing for use in automobiles to generate the high current necessary to start the

engine at a cheap cost. The battery's chemical energy is stored in a charged state at the

pure lead cathode and the PbO2 anode, as well as the potential difference between the

aqueous sulfuric acid solution. The energy released when the water molecules form a

strong chemical bond (H2O) with the H+ ion of the acid and the O2 ions of PbO2 to the power

produced by the drained lead-acid battery. Instead, the battery works as a moisture

dispersal mechanism during charging.

Fig 6.12: Lead Acid 12v Rechargeable Battery


• Brand Amptek

• Battery Type Acid Lead Battery

• Voltage 12V

• Initial Current Less Than 0.88A

• Capacity 2AH

• Output Type Dual

• Timing 20Hr

• Standby Use 13.6-13.8v



6.1.11 12V Dc Motor:

A DC motor is any spinning electric motor that transforms direct current (DC) power into

mechanical energy. The most common uses magnetic fields to produce force. Almost all

DC motors feature an inbuilt electromechanical or electronic system that adjusts the

current direction in one portion of the motor on a continuous basis. DC motors were the

first extensively used motors. Small motor is used in toys, tools, and home appliances.

Universal motors are small direct current motors that are found in portable electrical

equipment and gadgets. Large direct current motors are used to power electric vehicles,

elevators and hoists, and steelworks. Power electronics have made it feasible to replace

DC motors with AC motors in a range of applications.

Fig 6.13: Dc Motor


• Shaft length: 22mm

• Voltage: 4V to 12V

• Shaft diameter: 6mm

• Gear assembly: Spur

• Stall torque: 28 Kg-cm

• Motor weight: 143gms

• RPM: 30 at 12v

• Brush type: Carbon



6.2 List of Materials

Sl. No. PARTS Qty. Material

i. Double Acting Pneumatic Cylinder 2 M.S

ii. Solenoid Valve 1 Aluminum

iii. Frame 1 MS

iv DC motor 1 Aluminum

v. DC battery 1 cu

vi. Polyethylene Tube - Polyurethane

vii. Hose Collar and connector - Brass

viii Wheels 4 rubber

ix Controller unit 1

Table 6.1 List of Materials

6.3 Material Cost:

Sl. No. PARTS Qty. Material Amount (Rs)

i. Double Acting Pneumatic Cylinder 2 M.S 3920

ii. Solenoid Valve 1 Aluminum 1199

iii. Frame 1 MS 7500

iv DC motor 1 Allu 850

v. DC battery 1 cu 767

vi. Polyethylene Tube - Polyurethane 130

vii. Hose Collar and connector - Brass 450

viii Wheels 4 rubber 1600

ix Controller unit 1 1020

TOTAL = Rs. 17,436/-

Table 6.2 Material Cost



• Labour Cost

Welding, Grinding, Power Hacksaw, Gas Cutting:

Cost = Rs. 4,000/-

• Overhead Charges

Overhead Charges = Rs. 900/-

• Total Cost

Total cost = Material Cost + Labour cost + Overhead Charges

= 17,436 + 4,000 + 900

= 22,336/-

Total cost for this project = Rs. 22,336/-

6.4 Advantages:

With the aid of this invention, a driver can select the ground clearance that best

suits his driving comfort and the terrain.

Lowering ground clearance while driving on a road makes riding off-road easier and

increases fuel efficiency.

For off-road tracks, one can move along the path of the road with superior handling

and the maximum clearance possible. However, for on-road tracks, lowering ground

clearance allows us to experience the delight of driving an on-road car.

This technology aids in the vehicle's understeering. The technology is incredibly

easy to use. A vehicle's economy will improve thanks to this method. Complexity is raised

as a result. The technology is quite dependable when in use.

6.5 Applications

The system has good market potential because it is more user-friendly while also

delivering increased performance. GPS in the car may communicate with active safety

suspension.

When a self-driving car detects or anticipates rough terrain, the suspension may

send a command to the self-driving control system to change lanes or head in a different

direction.



CHAPTER – 7

RESULTS AND DISCUSSIONS

7.1 Catia Design

Fig 7.1 Isometric View

Fig 7.2 Side View



Fig 7.3 Bottom View

Fig 7.4 Front View

Fig 7.5 Top View



7.2 Catia Drafting

Fig 7.6 Catia Drafting



7.3 Block Diagram

Fig 7.7 Block Diagram



7.4 Flow Chart

Fig 7.8 Flow Chart



7.5 Coding (Arduino IDE)



7.6 Calculations

• Design of Piston Rod:

Load due to air Pressure.

Diameter of the Piston (d) Pressure acting (p) Material used for rod Yield stress (σy) Assuming factor of safety

= = = = =

40 mm 6 kgf/cm² C 45 36 kgf/mm² 2

Force acting on the rod (P)

P

= = = =

Pressure x Area p x (Πd² / 4) 6 x {(Π x 4²) / 4} 73.36 Kgf

Design Stress(σy)

= σy / F0 S =

= =

36 / 2 18 Kgf/mm²

P / (Π d² / 4)

∴ d

= =

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

∴ Minimum diameter of rod required for the load

=

2.3 mm

We assume diameter of the rod = 15 mm

• Design of cylinder thickness:

Material used Assuming internal diameter of the cylinder Ultimate tensile stress

= = =

Cast iron 40 mm

250 N/mm² = 2500 gf/mm² Working Stress = Ultimate tensile stress / factor of safety

Assuming factor of safety = 4

Working stress (ft) = =

2500 / 4 625 Kgf/cm²



According to ‘LAMES EQUATION’

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

Were,

ri = inner radius of cylinder in cm. ft = Working stress (Kgf/cm²) p = Working pressure in Kgf/cm²

Substituting values we get,

t = 2.0 {√ (625 + 6) / (625 – 6) -1} 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

• 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



CHAPTER – 8

CONCLUSION AND FUTURE SCOPE

8.1 Conclusion

Our primary goal in developing this system was to enhance accident prevention

methods while also lowering the risk associated with accidents, such as vehicle damage

and human injury. We saw that all of the necessary goals were accomplished by our work.

Cars with air bags always have a high initial cost. High end cars typically come with air

suspension. By putting this proposal into action, we can make smaller, more affordable

cars safer. Air bags are useful for providing internal safety to passengers in a car, but in our

project, we'll also give external safety to protect the automobile from harm.

Thus, providing better safety for a cheaper cost. The proposed system of pothole

and hump recognition using ultrasonic senor is being executed by fixing the assembly on a

vehicle and the received output in the form of alarm is given to the driver.

8.2 Future Scope

• To maintain ergonomics in the vehicle, thereby providing smoother travel

experience. • Vehicle to vehicle communications. • High precision maps for road conditions can be updated.



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