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

modern machine shops and space robots. An extendable and retractable bumper
(E/R bumper) is presented in this project. The aim is to design and develop a
control system based intelligent electronically controlled automotive bumper
activation is called AUTOMATIC PNEUMATIC BUMPER SYSTEM . The
E/R bumper is intended to automatically extend in situations in which there is a
high risk of frontal impact to prepare the vehicle for crash and retract when the
risk subsides.
This bumper system is only activated the vehicle speed above 30-40 km per
hour. This vehicle speed is sensed by the proximity sensor and this signal is
given to the control unit and pneumatic bumper system
I.INTRODUCTION

The structures and interiors of modern motor vehicles are designed to prepare
for a crash full time although crashes are relatively rare events. Full time
readiness for a crash has imposed stringent restrictions on the styling, design
and utility of motor vehicles. With the advancement in sensing technologies, a
new class of safety features, called crash preparation features, has shown great
potential in relieving the design restrictions. “Crash preparation” is the timely
reconfiguration of a vehicle’s structure and interior to the crash-ready state
before an imminent crash. If the threat of a crash subsides, the vehicle reverts to
its normal driving state, i.e., a “less” crash-ready state. Crash preparation can
offer the needed crash protection while allowing new styling, design and utility
previously not possible due to the needs for crash protection.

II.NEED FOR AUTOMATION

Automation can be achieved through computers, hydraulics, pneumatics,

robotics, etc., of these sources, pneumatics form an attractive medium for low
cost automation. The main advantages of all pneumatic systems are economy
and simplicity. Automation plays an important role in mass production.
For mass production of the product, the machining operations decide the
sequence of machining. The machines designed for producing a particular
product are called transfer machines. The components must be moved
automatically from the bins to various machines sequentially and the final
component can be placed separately for packaging. Materials can also be
repeatedly transferred from the moving conveyors to the work place and vice
versa.
Nowadays almost all the manufacturing process is being atomized in order to
deliver the products at a faster rate. The manufacturing operation is being
atomized for the following reasons.
※ To achieve mass production
※ To reduce man power
※ To increase the efficiency of the plant
※ To reduce the work load
※ To reduce the production cost
※ To reduce the production time
※ To reduce the material handling
※ To reduce the fatigue of workers
※ To achieve good product quality
 III. SELECTION OF PNEUMATICS

GENERAL DETAILS OF PNEUMATICS

PNEUMATIC CYLINDER

Introduction
A pneumatic cylinder simply converts air pressure into linear motion.

FACTOR TO BE CONSIDERED FOR THE SELECTION OF

PNEUMATIC CYLINDERS

When selecting a pneumatic cylinder, you must pay attention to:

 how far the piston extends when activated, known as "stroke"

 surface area of the piston face, known as "bore size"
 action type
 pressure rating, such as "50 PSI"
 type of connection to each port, such as "1/4" NPT"
 must be rated for compressed air use
 mounting method

Action Types
By "action type", we mean how the cylinder acts when pressure is applied and
removed.
A "single-acting" cylinder has a single port for compressed air.

When air pressure is removed, the cylinder does nothing to retract the piston.
Whatever the piston pushed out must push the piston back in.
A cylinder that is "single-acting with spring return" has hookups like the "single-
acting" cylinder.

When air pressure is removed, the spring pushes the piston back into the resting
position.
In some cases the cylinder is sealed and the trapped air performs as an "air spring".

A single-acting cylinder with spring return requires more air pressure to activate
because you are pushing against both the load and the spring.

A "double-acting" cylinder has two ports for compressed air.

Note that a double-acting cylinder requires a more complex solenoid valve. When
you want to return the piston to its resting position, you must not only apply
pressure to the second port, but also open up the first port so that the gas in it can
be expelled.

A double-acting cylinder consumes more air than the equivalent single-acting

cylinder, because you need air to push the cylinder in each direction.

Commercial Pneumatic Cylinders

Pneumatic cylinders are available commercially in a wide range of sizes and

designs.

Using a commercial pneumatic cylinder is not a guarantee of safety - you can still
do bad things with good parts - but it does provide additional safety margins that
improviced pneumatic cylinders simply can not provide.

Commercial pneumatic cylinders are surprisingly affordable and easy to find.

HEAVY DUTY PNEUMATIC CYLINDER

Heavy-Duty Pneumatic
Cylinder

Utility through air power

Change s and
improvements in the electric
motor industry have produced
linear motors making deep incursions in places where hydraulic cylinders
formerly held sway. Hydraulic systems are great for brute force operations but
are difficult to keep clean, and high pressures in some applications can pose a
hazard for work crews. The working fluid is also toxic to the environment, so
accidents can be costly to clean. On the other hand, electric motors can be
precisely controlled but command a higher cost.

Now an alternative to both approaches is offered by Numatics, Franklin,

TN, in the shape of their In Force cylinder line. The first member under that
sobriquet is the ASP Series, designed to function in strenuous cylinder
applications, such as packaging equipment, industrial furnaces, construction
equipment, and automotive and motorcycle assembly lines. The steel cylinder is
honed to a fine finish and then surface hardened by a Nitrotec process, which
creates a thin (0.001-in.), uniform and extremely hard (64 to 71 Rc) iron nitride
layer infused with a film of iron oxide. The result is a smooth, corrosion-free
sealing surface and high abrasion resistance.

For added ruggedness, the ASP Series includes a graphite-filled, cast iron
rod bushing made to a greater length than in standard cylinders. The use of cast
iron provides maximum resistance against premature wear, while the added
length adds improved alignment and support of the piston rod, as well as
providing maximum load bearing support. The high-strength steel (100,000 psi
min. yield) piston rod, in diameters from 5/8- to 3½-in., has a ground, polished
and chrome-plated surface, which provides maximum life for both the rod
bushing and the seals. The piston seal is carboxilated nitrile with Teflon
compound for self-lubrication. The “T “ seal configuration with back-up rings
prevents rolling, and seals at all pressures. All units in the ASP Series include a
wear band, a stable lubricating strip located on the piston (the latter made of
aluminum, the only non-steel component in the assembly). To maximize
separation between load bearing points, the band was placed at the rear of the
piston. The end caps are machined from precision square steel blocks and have a
black oxide finish for corrosion protection. Additionally, a recess on both ends of
the piston-mating surface enables the air to work on a larger piston area for
effortless breakaway, even at low pressures.
 The ASP Series of pneumatic cylinders has a nominal pressure rating of
250 psi, and is being offered initially in eleven bore sizes from 1.5- through 14.0-
in. Standard operating temperatures are -10° to 165°F. There are 21 standard
NFPA mounting options, all accomplished with one-piece mounts on units with
bores up to 8.0 in.; i.e., there are no welded-on lugs. The NPTF ports have an
enhanced design for a smooth flow path into and out of the cylinder. Options
include stroke adjusters, high temperature rod
boots and more.

Pneumatic cylinders

Pneumatic cylinders or air cylinders are mechanical devices used to impart a

force from a fluid, typically compressed air.

Pneumatic cylinders are available in a variety of styles, including tie rod,

compact, round body, rotary, gripper, escapement, guided, and rodless cylinders.
Other features of pneumatic actuators include the ability to have multiple strokes
or a full stroke with intermediate stopping points, adjustments to control the
amount of extension or retraction of a given actuator, and locks that can serve as
safety mechanisms in case the machine experiences a loss of air pressure.

A typical pneumatic cylinder consists of a piston, piston rod, and a body or

tube. Compressed air enters at one end of the tube, imparting force on the piston,
which is then displaced (moves) in order to balance the force exerted on the
piston. Air cylinders, or actuators as they are also called, are available in a variety
of sizes, shapes, and have varying strokes. Typical cylinder sizes range from a
small 2.5mm air cylinder, which might be used for picking up a small transitor or
other electronic component, to 400mm diameter air cylinders which would impart
enough force to lift a car. Some pneumatic cylinders reach 1000mm in diameter,
and are used in place of hydraulic cylinders for special circumstances where
leaking hydraulic oil could impose an extreme hazard.

Air Cylinders are available in a variety of styles. Some examples include:

Single acting cylinders--cylinders that use the force imparted by air to move in one
direction, and a spring to return to the "home" position. Double acting cylinders--
cylinders that use the force of air to move in both extend and retract strokes.
Rotary air cylinders--actuators that use air to impart a rotary motion Rodless air
cylinders--actuators that use a mechanical or magnetic coupling to impart force,
tyically to a table or other body that moves along the length of the cylinder body,
but does not extend beyond it.

Pneumatic cylinders are generally less expensive than hydraulic or electric

cylinders of similar size and capacity.

Mechanization is broadly defined as the replacement of manual effort by

mechanical power. Pneumatics is an attractive medium for low cost
mechanization particularly for sequential or repetitive operations. Many
factories and plants already have a compressed air system, which is capable of
providing both the power or energy requirements and the control system
(although equally pneumatic control systems may be economic and can be
advantageously applied to other forms of power).

IV. IR SENSOR

A sensor is a transducer used to make a measurement of a physical variable.

Any sensor requires calibration in order to be useful as a measuring device.
Calibration is the procedure by which the relationship between the measured
variable and the converted output signal is established.

Care should be taken in the choice of sensory devices for particular tasks. The
operating characteristics of each device should be closely matched to the task
for which it is being utilized. Different sensors can be used in different ways to
sense same conditions and the same sensors can be used in different ways to
sense different conditions.
In our project IR transmitter and IR receiver are used to detect the obstacle.
These sensors are fitted at the front side of the vehicle.

IR TRANSMITTER:

The IR transmitting circuit is used in many projects. The IR transmitter sends

40 kHz (frequency can be adjusted) carrier under 555 timer control. IR carriers
at around 40 kHz carrier frequencies are widely used in TV remote controlling
and ICs for receiving these signals are quite easily available.

FIG 2. IR SENSOR RAYS

IR RECEIVER

The transmitted signal reflected by the obstacle and the IR receiver circuit
receives the signal and giving control signal to the control unit. The control unit
activates the pneumatic breaking system, so that break was applied.
V. COMPONENTS

The pneumatic bearing press consists of the following components to fulfill the
requirements of complete operation of the machine.

1) PNEUMATIC SINGLE ACTING CYCLINDER

2) SOLENOID VALVE
3) FLOW CONTROL VALVE
4) WHEEL ARRANGEMENT
5) STAND

1) PNEUMATIC SINGLE ACTING

CYLINDER:

2) Pneumatic cylinder consist of

A) PISTONB) CYLINDER
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 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.

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: Aluminium
Parts of Pneumatic

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.

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.

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 of friction and should be able to withstand the
high compressor force developed in the cylinder and also the shock load during
operation.
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.

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 arrangements prevent the leakage of air from the bottom of the
cylinder while the rod reciprocates through it.

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. 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.
2. SOLENOID VALVE WITH CONTROL UNIT:

The directional valve is one of the important parts of a pneumatic system.

Commonly known as DCV, this valve is used to control the direction of air flow
in the pneumatic system. The directional valve does this by changing the
position of its internal movable parts.

This valve was selected for speedy operation and to reduce the manual effort
and also for the modification of the machine into automatic machine by means
of using a solenoid valve. A solenoid is an electrical device that converts
electrical energy into straight line motion and force. These are also used to
operate a mechanical operation which in turn operates the valve mechanism.
Solenoids may be push type or pull type. The push type solenoid is one in
which the plunger is pushed when the solenoid is energized electrically. The
pull type solenoid is one is which the plunger is pulled when the solenoid is
energized.
The name of the parts of the solenoid should be learned so that they can be
recognized when called upon to make repairs, to do service work or to install
them.

 Parts of a Solenoid Valve

1. Coil

The solenoid coil is made of copper wire. The layers of wire are separated by
insulating layer. The entire solenoid coil is covered with an varnish that is not
affected by solvents, moisture, cutting oil or often fluids. Coils are rated in
various voltages such as 115 volts AC, 230 volts AC, 460 volts AC, 575 Volts
AC, 6 Volts DC, 12 Volts DC, 24 Volts DC, 115 Volts DC & 230 Volts DC.
They are designed for such frequencies as 50 Hz to 60 Hz.

2. Frame

The solenoid frame serves several purposes. Since it is made of laminated

sheets, it is magnetized when the current passes through the coil. The
magnetized coil attracts the metal plunger to move. The frame has provisions
for attaching the mounting. They are usually bolted or welded to the frame.
The frame has provisions for receivers, the plunger. The wear strips are
mounted to the solenoid frame, and are made of materials such as metal or
impregnated less fiber cloth.

3. Solenoid Plunger

The Solenoid plunger is the mover mechanism of the solenoid. The plunger is
made of steel laminations which are riveted together under high pressure, so
that there will be no movement of the lamination with respect to one another.
At the top of the plunger a pin hole is placed for making a connection to some
device. The solenoid plunger is moved by a magnetic force in one direction and
is usually returned by spring action.

Solenoid
operated valves are usually provided with cover over either the solenoid or the
entire valve. This protects the solenoid from dirt and other foreign matter, and
protects the actuator. In many applications it is necessary to use explosion proof
solenoids.

3. FLOW CONTROL VALVE:

This valve is used to speed up the piston movement and also it acts as an one –
way restriction valve which means that the air can pass through only one way
and it can’t return back. By using this valve the time consumption is reduced
because of the faster movement of the piston

4. WHEEL ARRANGEMENT:

The simple wheel and braking arrangement is fixed to the frame stand.
5. STAND:

This is a supporting frame and made up of mild steel.

6. WORKING OPERATION

The impartant components of our project are,

IR
transmit

ter

IR
receiver
Control Unit with
Power supply
Solenoid Valve
Flow control ValveAir Tank (Compressor)
The IR TRANSMITTER circuit is to transmitter the Infra-Red rays. If any

obstacle is there in a path, the Infra- Red rays reflected. This reflected Infra-Red
rays are received by the receiver circuit is called “IR RECEIVER”.
The IR receiver circuir receives the reflected IR rays and giving the control
signal to the control circuit. The control circuit is used to activate the solenoid
valve. The operating principle of solenoid valve is already explained in the
above chapter. If the solenoid valve is activated, the compressed air passes to
the Single Acting Pneumatic Cylinder. The compressed air activate the
pneumatic cylinder and moves the piston rod.

If the piston moves forward, then the breaking arrangement activated. The
breaking arrangement is used to break the wheel gradually or suddenly due to
the pistion movement. The breaking speed is varied by adjesting the valve is
called “FLOW CONTROL VALVE”.

In our project, we have to apply this arrangement in one wheel as a model. The
compressed air drawn from the compressor in our project. The compressed air
flow through the Polyurethene tube to the flow control valve. The flow control
valve is connected to the solenoid valve as mentioned in the block diagram
.
7. APPLICATIONS

For automobile
application
Industrial
application
8. ADVANTAGES

Free from wear

adjustment. Less
power
consumption
It gives simplified very
operation. Installation is
simplified very much

9. DISADVANTAGES

Additional cost is required to install this arrangement in the vehicle .

 CONCLUSION

This project work has provided us an excellent opportunity and experience, to

use our limited knowledge. We gained 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.
We are proud that we have completed the work with the limited time
successfully. The PNEUMATIC BUMPER FOR FOUR WHEELER is
working with satisfactory conditions. We are able to understand the
difficulties in maintaining the tolerances and also quality. We have done to our
ability and skill making maximum use of available facilities.
REFERENCES
1. Dr. R.K. Bansal, A text book of Strength of Materials, Laxmi Publications (P)
Ltd.
2. R.S. Khurmi, J.K. Gupta, A textbook of Machine Design, S.Chand Publishing
House
(P) Ltd.
3. G.B.S. Narang, “Automobile Engineering”, Khanna Publishers, Delhi, 1991, pp
671.
4. William H. Crowse, “Automobile Engineering”.
5. Pneumatic Control System Stroll & Bernaud, Tata Mc Graw Hill
Publications, 1999.
6. Pneumatic System----Majumdhar, New Age India International (P) Ltd
Publishers, 1997.