DESIGN AND FABRICATION OF

PNEUMATIC BUMPER AND BREAK

ACTUATION BEFORE COLLISION

A PROJECT REPORT
Submitted by
V. AJITHKUMAR (621215114004)
JITHIN THOMAS (621215114019)
K. RAJENDRAPRASATH (621215114035)
A. SIVA (621215114042)

In partial fulfillment for the award of the degree

Of

BACHELOR OF ENGINEERING

in

MECHANICAL ENGINEERING

KING COLLEGE OF TECHNOLOGY

NAMAKKAL

ANNA UNIVERSITY : CHENNAI 600 025

APRIL – 2019

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 ANNA UNIVERSITY : CHENNAI 600 025

BONAFIDE CERTIFICATE

Certified that this project report “FABRICATION OF PNEUMATIC

BUMPER AND BRAKE ACTUATION BEFORE COLLISION” is the
bonafide work of “ V.AJITHKUMAR(621215114004)” who carried out the
project work under my supervision.

SIGNATURE SIGNATURE
Mr. M.BHOOPATHI, M.Tech., Mr. M.VEERAMANI, M.E.,
HEAD OF THE DEPARTMENT, SUPERVISOR,
Assistant Professor, Assistant Professor,
Dept. of Mechanical Engineering, Dept. of Mechanical Engineering,
King College of Technology, King College of Technology,
Namakkal-637020. Namakkal-637020.

Submitted for the viva-voce examination held on ……………….

Internal Examiner External Examiner

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 ACKNOWLEDGEMENT

First and foremost we would like to express thanks to our beloved founder
Mr.J.ILANGO,B.A.,B.L., and our beloved chairman
Mrs.KALAILANGO,B.com, and all the member of the management of
KING COLLEGE OF TECHNOLOGY for providing better working
environments and educational facilities in a well sophisticated manner.

We wish to convey our profound thanks to our beloved and Honorable

Principal Dr.M.P. SUDHESH KUMAR, M.E., Ph.D., for forwarding us to do
our project and offering adequate duration in completing our project work.

We thank the almighty, whose blessings moved us towards each step of

success. We thank Mr.M.BHOOPATHI, M.Tech., Honorable Head of the
Department for his constructive suggestions & encouragement during our
project. We record our deepest sense of gratitude and respect to our guide
Mr.N.VEERAMANI, M.E., for their help and co-operation in leading our
project work. And we express our sincere word of gratitude to our class
counselor and staff members of the Department of Mechanical Engineering,
King College of Technology.

We are very grateful to all the staff members and non-teaching members,
our families and classmate who directly or indirectly helped us to finish the
project successfully we would like to take this opportunity to express our
gratitude and to extend our best wishes for all who guided, inspired and
motivated us during this project.

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 ABSTRACT

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

automation and modern machine shops and space robots. The aim is to design
and develop a control system based intelligent electronically controlled
automotive bumper activation and automatic braking system is called
AUTOMATIC PNEUMATIC BUMPER AND BREAK ACTUATION BEFORE
COLLISION. This project consists of IR transmitter and Receiver circuit,
Control Unit, Pneumatic bumper system and pneumatic braking system. The IR
sensor senses the obstacle. There is any obstacle closer to the vehicle (within 1
feet), the control signal is given to the bumper activation system and also
pneumatic braking system simultaneously. The pneumatic bumper and braking
system is used to product the man and vehicle. This bumper and braking
activation system is only activated the vehicle speed above 20 km per hour. This
vehicle speed is sensed by the IR sensor and this signal is given to the control
unit and pneumatic bumper and braking activation system.

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 CONTENTS

CHAPTER TITLE PAGE. NO

ABSTRACT iv

LIST OF FIGURE vii

LIST OF TABLES viii

1 INTRODUCTION 1

2 LITERATURE REVIEW 2

3 WORKING PRINCIPLE 6

4 MAJOR COMPONENTS 8
4.1 SHAFT 8
4.2 METAL STRIP 11
4.3 BALL BEARING 13
4.4 PNEUMATIC CYLINDER 16
4.5 SOLENOID VALVE 21
4.6 HOSE & CONNECTOR 23
4.7 AIR TANK 24
4.8 IR SENSOR 27
4.9 RELAY 33
4.10 WHEEL 34

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5 METAL FRAME 43
5.1 MANUFACTURING PROCESS 44
5.1.1 SAWING 44
5.1.2 WELDING 46
5.1.3 DRILLING 47
6 ADVANTAGES & APPLICATIONS 48

7 MATERIALS & COST ESTIMATION 49

8 2D LAYOUT OF MODEL 52

9 CONCLUSION 53

10 REFERENCE 54

11 PHOTOGRAPHY 56

LIST OF FIGURES

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FIG.NO NAME OF THE FIGURE PAGE NO

4.1 SHAFT 8

4.2 METAL STRIP 11

4.3 BALL BEARING 12

4.4.1 PNEUMATIC CYLINDER 16

4.4.2 DOUBLE ACTING CYLINDER 18

4.5.1 DIAGRAMMATIC SOLENOID VALVE 21

4.5.2 SOLENOID VALVE 22

4.6.1 HOSE COUPLING 23

4.6.2 CONNECTOR 23

4.7.1 TWO STAGE AIR COMPRESSOR 25

4.7.2 SINGLE STAGE AIR COMPRESSOR 26

4.8 IR SENSOR 28

4.9.1 RELAY 33

4.9.2 PIN DIAGRAM 34

4.10.1 WHEEL 35

4.10.2 CROSS SECTION OF TIRE 39

5.1.1 MILD STEEL BARS 43

5.1.2 SAWING CUTTING MACHINE 45

5.1.3 WELDING OPERATION 46

LIST OF TABLES

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TABLE NO TABLE DESCRIPTION PAGE NO

4.7 DETAILS OF BRAND AIR COMPRESSOR 27

7.1 MATERIALS USED 49

7.2 COST ESTIMATION 50

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