FABRICATION OF UNCONVENTIONAL COMPRESSOR FOR HEAVY

TRUCK

(DEMO MODEL)

ABSTRACT

Introduction
Today in various automobile industries they prefer unconventional parts
to improve their productivity.
Scope objective
Now they use unconventional air compressor in heavy vehicle such as
tippers and trucks. Unlike standard air compressor it doesn’t have crank
shaft and connecting rod. It resembles the cycle foot pump. Operation is
simple which indeed serve the purpose fruitfully.
Working principle
When vehicle travels on the road, vibration is created due to bumpy
impact, imbalance tire wheel assembly or related to the mechanical
condition of the vehicle. These vibration created is purely a force
vibration which is an unwanted energy. We make use of these as prime
mover to our system. Compressed air produced by operation of this
system is mainly used for operation of pneumatic braking system, horn,
air intake system.
Besides above stated uses, it plays important role for hydraulic operated
automobiles as it has no air producing system. In this case we are able to
achieve whatever the pneumatic operation can be performed.
Here main advantage is that in heavy vehicle damper requirement is
neglected. Though there will be damper attached during manufacture but
it can be taken out as and when the unconventional air compressor is
implemented.
It is economical to use this unconventional air compressor in heavy
vehicle. It can also helps in reduction of air pollution.

SCHEMATIC DIAGRAM FOR UNCONVENTIONAL AIR

COMPRESSOR
Advantage

1) Engine BHP will increased

2) Energy resources is properly utilized over here

3) Maintenance is very low

Disadvantages

1) Pressure of the air is low compare to reciprocating compressorThe mains supply

is an alternating current in the form of a sine wave. The common power supply to
households is a single phase AC supply. The frequency and the amplitude of
the AC wave vary from region to region with 50 Hz or 60 Hz being the common
frequency and an amplitude of 110V or 240V.

The power rating of an electrical device or appliance will determine the power
utilized by it to work properly. What if we desire to reduce the intensity of an
electric bulb or run a motor at less speed? This can be achieved by limiting the
power to the device i.e. supplying less power than the maximum rated power.

This concept of restriction on the power supplied to a device is known as AC

power control. AC power control allows us to efficiently use the available power
for various applications.

There are two types of AC power control: ON-OFF or pulse skipping modulation
control and phase control. In on-off control, the load is connected to the AC
supply for short interval of time and the AC supply is switched off for some
interval.

A fast switching device like a thyristor is used to connect and disconnect the load
to the AC power supply. In phase control method, the load is connected to the
AC supply for a specific period of both the half cycles.

A PWM technique based AC power control is designed here which is a type of

on-off control. The circuit regulates the AC power supplied to any load like an
electric bulb, motor, amplifiers etc.
 Outline

 Circuit Diagram
 Components
 Component Description
o Arduino Uno Board
o GBPC 610
o IRGP4063
o CNY65
 Working
 Applications

Circuit Diagram

Components
Component Description

Arduino Uno Board

It is a microcontroller based prototyping board. The purpose of Arduino board in
this project is to generate the required PWM signal and also control the duty
cycle of the PWM signal with the help of switches to control the output power
delivered to the light bulb.

One of the digital I/O pins is used as a PWM output and four other digital I/O pins
are used as inputs from switches.

GBPC 610
It is a bridge type full wave rectifier used in AC to DC conversion.
IRGP4063
It is an IGBT (Insulated Gate Bipolar Transistor) with a rating of 600V and 96A
with a maximum power dissipation of 330W. The purpose of the IGBT in this
circuit is to act as a switch for switching the supply on and off according to the
duty cycle pf the PWM.

CNY65
It is an optocoupler IC which has a phototransistor which is optically coupled to
an LED (infrared light is emitted). It is used to isolate the weak PWM signal circuit
from the high voltage and high current transistor (IGBT or MOSFET).

Working
The aim of this circuit is to control the AC power supplied to an electrical device
like a light bulb with the help of pulse width modulated AC sine wave. The AC
power supply (240V @ 50Hz) is given to a bridge rectifier (BR1). This is further
rectified with the help of diode D1 and the filter circuit formed by the resistor R1
and capacitor C1.

The output of this filtered signal is a DC signal, which is given to the optocoupler
as DC voltage. A light bulb is connected in series with the bridge and the power
supply.

An Arduino Uno board is used to generate the PWM wave. Four switches are
used with the Arduino to select different duty cycles of PWM signal.

The four switches associated with the Arduino provide duty cycles of 0%, 25%,
50% and 75%. When no switch is pressed, maximum power is delivered to the
light bulb.

The PWM signal from the microcontroller (Arduino) is given to the input of an
Optocoupler (CNY65) with the transistor in the optocoupler connected to DC
voltage from the rectifier for quick conduction.

A resistor (R5) is used in series with the optocoupler to protect the IR emitting
diode in the optocoupler. Resistor R4 is used to reduce the switching spikes. The
purpose of the optocoupler is to isolate the low voltage PWM signal from the
large voltage and current in the transistor.

The output of the optocoupler is the same PWM signal from the microcontroller
(Arduino) and will act as the input signal applied to the gate of the transistor.

The transistor must be a high speed switching device which can handle large
power. Hence, a power MOSFET or IGBT can be used. The important thing to
remember when operating with MOSFET and PWM is that the MOSFET stays on

How PWM can be used to control the AC power? The most effective way to
control the AC power is to tune the frequency of the AC signal. Consider a
situation where a switch is present between the electrical device like a bulb and
the mains power supply.

If the switch is ON (or closed) for 2 seconds and OFF (or open) for 2 seconds,
then the power consumption is reduced by 50%.

If the switching action is so fast that it is not detected by the human eye, then the
light bulb will appear as it is continuously glowing with half the luminance and
consuming only 50% power. An IGBT or a MOSFET is used as a switch and the
switching action of the transistor is controlled by a pulse.

The on (high) and off (low) period of the pulse will determine whether the
transistor is switched on or off and consequently controlling the AC power and
this is how a PWM signal is used in AC power control.

The on and off periods of the PWM wave define a factor called Duty cycle and
this is an important parameter in controlling the power.

A 50% duty cycle PWM wave will provide only 50% of the maximum power and a
33% duty cycle PWM will deliver only 33% of the maximum power.

An important thing to be considered when choosing the switching device is that it

should have a fast switching action and also should be capable of handling large
power.

Note
  The circuit mentioned here can be used with light bulbs. Inductive loads
like motors cannot be used as the circuit is DC biased.
 Zero cross detection circuit can be used but this might keep the
microcontroller very busy as it has to continuously monitor for zero
crossing.
 MOSFETS can also be used in place of IGBT but MOSFETS the heat
dissipation is better in case of IGBT.
 The position of the lamp can be moved and placed at the drain of the
transistor.
 In case of any flickers, a 100µH inductor can be used in the output path.

Applications
 This circuit can be used to control the AC power supplied an electrical
device.
 Slight modifications in the circuit will allow it to control AC power to
inductive loads like motors.
 Can be used to save the AC power as it can regulate the power supplied to
the electrical device.