AUTOMATIC TIRE INFLATION SYSTEM

A PROJECT REPORT

Submitted by:

AKSHIT CHANDEL (20BAM1031)

EAK NARAYAN DHAKAL (20BAM1021)
WILFRED BUKROH (20BAM1027)

In partial fulfillment of the award of the

Degree of

BACHELOR OF ENGINEERING
IN

AUTOMOBILE ENGINEERING

Chandigarh University
APRIL 202
 BONAFIDE CERTIFICATE

Certified that this project report “AUTOMATIC TIRE INFLATION

SYSTEM” is the bonafide work of AKSHIT CHANDEL, EAK
NARAYAN DHAKAL, WILFRED BUKROH who carried out the
project work under my /our supervision.

SIGNATURE SIGNATURE

Prof (Dr) Navdeep Sharma Dugala Er. Deepak Kapila

SUPERVISOR

HEAD OF THE DEPARTMENT Assistant Professor

Automobile Engineering Automobile Engineering

Submitted for the viva-voice examination held on 26th April 2024

INTERNAL EXAMINER EXTERNAL EXAMINER

 ACKNOWLEDGEMENT
We feel extremely proud and privileged to present our report on the Project Work we undertook
during the B.Tech. Automobile engineering 8 th semester. Our group would like to express our
sincerest gratitude to Assistant Prof. Deepak Kapila, the Project Coordinator, from the
Department of Automobile Engineering at Chandigarh University for his unwavering support
and guidance throughout the project's duration. His efforts played a pivotal role in the successful
completion of our project, and we are immensely grateful to him for his guidance and direction.
We would also like to extend our deepest appreciation to Assistant Prof. Deepak Kapila and the
Automobile Engineering Department at Chandigarh University for serving as the Guide of our
project. Their diligent efforts in guiding and correcting various documents with immense
attention and care helped us hone our skills and improve our project's quality. Their invaluable
contribution made a significant difference in the project's overall success, and we are grateful for
their support.
We would also like to acknowledge the Director of Chandigarh University and the Assistant
Professor and co-coordinator of the Department of Information Technology for their unwavering
support and guidance during the project's development. Their assistance was critical in ensuring
that we met our project goals and objectives.
We would also like to express our gratitude to all the faculty members of the department who
provided us with their kind assistance and cooperation during the project's development. Their
guidance and support enabled us to overcome challenges and reach our project milestones.
we would like to acknowledge the contributions of our friends and group members, who played
a crucial role in the successful completion of our project. We couldn't have achieved this feat
without their hard work, dedication, and commitment.
In conclusion, we would like to express our sincere gratitude to everyone who contributed to the
project's success, and we look forward to applying the knowledge and experience gained during
this project to future endeavors.
 TABLE OF CONTENTS

Contents Page no.

List of Figures i
List of Tables ii
ABSTRACT iii
CHAPTER-1 1
INTRODUCTION 1
1.1 Tire Inflation Basics 1
1.2 Project Motivation 2
1.3 Tire Wear, Fuel Economy, Performance, and Safety 4
1.4 Beneficiaries 5
1.3 Importance of Automatic Tire Inflation System 5
CHAPTER - 2 7
OBJECTIVES AND SPECIFICATIONS 7
2.1 Design Objectives 7
2.2 Ability to provide proper tire pressure 7
2.3 Minimize Negative Visual Aesthetics 8
2.4 Ability to Provide Automatic System 9
2.5 Low-Cost Device 10
2.6 Methodology 10
2.7 Specifications 11
2.8 Limitations 11
CHAPTER-3 12
LITERATURE SURVEY 12
3.1 Literature Review 12
3.2 History 13
3.2.1 Michelin's Use of Central Tire Inflation Systems (CTIS) for Agricultural Purposes 14
CHAPTER - 4 16
HARDWARE DESCRIPTION 16
4.1 Layout of Tire Inflation System 16
4.2 Portable Compressor 16
4.3 Solenoid Valves (In Future) 17
4.4 Pressure Sensor (In Future) 18
4.5 Rotary Joint 19
4.6 Pressure Switch 21
4.7 Car Battery 12 V 22
4.8 Central Tire Inflation System (CTIS) ( In Future) 23
CHAPTER - 5 25
MATERIAL SELECTION AND DETAILS 25
5.1 Material Selection 25
5.2 Bright Material 28
5.3 Raw and Standard Material 29
CHAPTER - 6 30
MACHINE DESIGN 30
6.1 Introduction 30
6.2 Concept in M.D.P. 31
6.3 General Procedure in Machine Design 32
CHAPTER - 7 34
COST ESTIMATION SOFTWARE DESCRIPTION 34
7.1 Purpose of Cost Estimating 34
7.2 Material Cost Estimation 35
7.3 Machining Cost Estimation 35
7.4 Procedure for Calculation of Material Cost 36
7.5 Labour Cost 36
7.6 Raw Material & Standard Material 38
7.7 Software Description 39
CHAPTER - 8 40
ADVANTAGES AND FUTURE SCOPE 40
8.1 Advantages 40
8.2 Future Scope 41
8.3 Automotive Automatic Tire Inflation System Market Value, Trends [2029], Economy,
Expansion, Leader 42
8.4 Global Automotive Automatic Tire Inflation System Market 44
8.5 Major companies operating in the Global Automotive Automatic Tire Inflation
System Market are: 45
CHAPTER - 9 46
CONCLUSION 46
REFERENCES 47
 List of Figures

Figure no Figure name Page no

Figure 1.1 Tire contact patch geometry 11
Figure 1.2 Difficult to Notice Under-Inflated Tire 12

Figure 2.1 Construction diagram 19

Figure 3.1 Survey report (Pie-chart) 21
Figure 4.1 Tire Inflation System Configuration 25

Figure 4.2 12V Car Electric Air Compressor 26

Figure 4.3 The 2/2 Solenoid Valves 27
Figure 4.4 The inbuilt tire pressure sensor 27
Figure 4.5 The cross-sectional View of the Rotary Joint 29

Figure 4.6 The labeled diagram of the Rotary Joint 29

Figure 4.7 The Pressure Switch 30

Figure 4.8 The 12V Car Battery. 31

Figure 4.9 Central Tire Inflation System (CTIS) 32

i
 List of Tables

Table no. Table name Page no

Table 2.1 Component and Description 20

Table 5.1 Raw and standard material 38

Table 7.1 Material used 47

ii
 ABSTRACT
This abstract provides a concise summary of the project report on the Automatic Tire Inflation
System (ATIS). The ATIS is a critical technology aimed at maintaining optimal tire pressure in
vehicles without manual intervention, thereby enhancing fuel efficiency, extending tire lifespan,
and ensuring safety on the road.

The project objectives encompassed the design, development, and implementation of an ATIS
prototype capable of seamlessly integrating into various vehicle types and tire sizes.
Methodologically, a comprehensive approach was adopted, involving sensor placement, control
unit design, compressor selection, and valve regulation strategies.

Extensive testing, both in laboratory and real-world driving conditions, was conducted to
validate the system's performance. Results indicate significant improvements in tire pressure
maintenance, with a notable reduction in instances of underinflated tires. Furthermore, the ATIS
demonstrated enhanced fuel efficiency and contributed to vehicle safety by mitigating the risk of
accidents associated with tire-related issues.

In conclusion, the project successfully achieved its objectives, presenting a reliable and efficient
solution in the form of an Automatic Tire Inflation System. Future research avenues include
further refinement of the system, integration with vehicle telemetry, and collaboration with
automotive manufacturers for widespread adoption.

iii
 CHAPTER-1

INTRODUCTION

1.1 Tire Inflation Basics

According to AAA, about 80 percent of the cars on the road are driving with one or more tires
under-inflated. Tires lose air through normal driving (especially after hitting potholes or curbs),
permeation, and seasonal temperature changes. They can lose one or two psi (pounds per square
inch) each month in the winter and even more in the summer. And, you can't tell if they're
properly inflated just by looking at them. You have to use a tire pressure gauge. Not only is
under inflation bad for your tires but it's also bad for your gas mileage, affects the way your car
handles and is generally unsafe. When tires are underinflated, the tread wears more quickly.
According to Goodyear, this equates to 15 percent fewer miles you can drive on them for every
20 percent that they're underinflated. Under-inflated tires also overheat more quickly than
properly inflated tires, which causes more tire damage. The faded areas below indicate areas of
excessive tread wear.

The use of automobiles has been increasing day by day. Humans are completely reliant on
automobiles for transport purposes. In today’s competitive automobile sector; various
automobile industries are competing with each other to win the hearts of humans. To do so the
companies are making the system more effective by improving the safety systems in cars. The
more reliable the system is, the more successful the car becomes.

Since the discovery of wheels by man, it has been used extensively for a variety of purposes.
Wheels have become a vital part of human lives for ages. The effective use of wheels with more
innovative ideas further developed with developing technologies. One such upcoming
technology is the automatic air inflation system used in automobiles. This system is used to
maintain the pressure of tires in running condition.

The best application of such an automatic air inflation system is in military vehicles. Military
vehicles are supposed to run on various environmental conditions; where land conditions are

1
continuously changing. Such vehicles are supposed to be operated in the worst conditions such
as heavy rainfall, snowfall & deserts. At such remote places tire maintenance stations are not
available. In such crucial conditions, such systems serve as a boon for the users.

Figure 1.1 Tire contact patch geometry

Because tires are flexible, they flatten at the bottom when they roll. This contact patch rebounds
to its original shape once it is no longer in contact with the ground. This rebound creates a wave
of motion along with some friction. When there is less air in the tire, that wave is larger and the
friction created is greater -- and friction creates heat. If enough heat is generated, the rubber that
holds the tire's cords together begins to melt and the tire fails. See how tire works to learn more.
Because of the extra resistance an under-inflatedtire has when it rolls, your car's engine has to
work harder. AAA statistics show that tires that are underinflated by as little as 2 psi reduce fuel
efficiency by 10 percent. Over a year of driving, that can amount to several hundred dollars in
extra gas purchases.

1.2 Project Motivation

Improperly inflated tires are fairly common problems in passenger vehicles, 80% of passenger
vehicles on the road have at least one under-inflated tire and 36% of passenger cars have at least

2
one tire that is 20% or more under-inflated. Often pressure loss in tires is a result of natural
permeation of the gas through the elastic rubber, road conditions (such as potholes), and seasonal
changes in temperature (According to Weissler of Popular Mechanics, for every drop of 10 ºF,
tire pressure drops by1 psi ). Most vehicle owners are unaware of the fact that their tires are not
at the correct pressures because it is difficult to determine the tire pressure visually; a tire that is
properly inflated to the correct pressure looks very similar to one that is either over-inflated or
under-inflated (Fig).
According to the Rubber Manufacturing Association (RMA) survey, 80% of people are unsure of
how to check their tire pressures. Thus, from the viewpoint of passenger vehicle owners, they are
losing money due to increased tire wear and decreased fuel efficiency, and a solution needs to be
found to correct this issue. From the viewpoint of the designers, however, the root cause of
improperly inflated tires is due to vehicle owners not knowing proper tire pressures for certain
conditions, difficulty finding an air pump, lack of pressure measuring device, and a general lack
of concern. Thus, the combination of the user and expert viewpoints will be used to make
decisions in the design process of this product.

Figure 1.2 Difficult to Notice Under-Inflated Tire

In this case, the tire on the left is 31% under-inflated from the tire that is at nominal pressure on
the right.

3
1.3 Tire Wear, Fuel Economy, Performance, and Safety
An under-inflated tire can have dramatic effects on tire wear. Since the contact patch of the tire
has a larger wave pattern, friction and heat increase cause the contact patch to wear out more
quickly than if the tire was inflated properly. “Goodyear estimated that a tire’s average tread life
would drop to 68 percent of the expected tread life if tire pressure dropped from 35 psi to 17 psi
and remained there”. According to an unpublished study by Goodyear, the average cost for a tire
is $61.00, and the average tread life is 45,000 miles. Thus, at an average cost of $61.00/tire, and
given the circumstance that the owner keeps a vehicle for 100,000 miles, the owner will have to
change the tires three times instead of twice. The owner would then be paying $244 more for
tires, and in both situations, the most recently installed tires will only have approximately 10,000
miles of use.
Doran Manufacturing offers more statistics regarding the effects of under-inflated tires:
 20% under-inflation can reduce tire life by 30%
 20% under-inflation can increase tire wear by 25%
The fuel economy is also greatly affected by under-inflated tires. According to fueleconomy.gov,
an under inflation of 1 psi in all four tires on a passenger vehicle reduces efficiency by 0.4%.
Based on average gas prices, there is a potential of 3.3% in savings, which translates to $0.09 per
gallon.
As vehicle speeds increase, the tire pressures should also increase accordingly to reduce rolling
resistance (which improves fuel economy) and to limit damage due to the increased frequency of
tire profile deflections. Since highways are typically smoother than local roads, increasing the
tire pressure will not negatively impact ride quality in terms of noise and vibrations.
Properly inflated tires also have a significant effect on safety; the reduction in tire wear and
increase in vehicle safety are strongly correlated. 660 deaths and approximately 33,000 injuries
per year are associated with under-inflated tires according to National Highway Traffic Safety
Administration (NHTSA). Worn-outtires have a significant negative impact on traction in all
weather conditions. Under-inflated tires also increase the stopping distance of vehicles on both
dry and wet roads. At the same time, drivers would also “find a noteworthy loss of steering
precision and cornering stability”.
Additionally, heat build-up and the wear of the tire structure can cause a sudden unexpected

4
blowout on the highways, which is a common cause of many accidents.

5
1.4 Beneficiaries
As previously mentioned, the main beneficiaries of this advancement in technology that will
allow for tire pressure to be adjusted for driving conditions will be the vehicle owners. Despite
an initial investment in the technology, they will experience a reduction in tire wear and an
increase in fuel economy; both of which will result in saving money in the long run. It is
plausible to say that society as a whole will benefit from the resulting design. The reduction in
tire disposal in landfills and the decrease in the rate of consumption of natural resources will
truly benefit society. Also, the improvement in vehicle safety will benefit all people who drive a
vehicle on the roadways.
However, not everyone will benefit from this technology. Both tire manufacturers and the
petroleum industry will be negatively affected by this resulting design. Tire manufacturers will
be negatively affected since this product is being designed with the reduction of tire wear in
mind. The demand for their products will decrease as tires last longer and fewer replacements are
needed. This is similarly true for the petroleum industry since this product results in an increase
in fuel economy for passenger vehicles, and the oil demand will go down.

1.3 Importance of Automatic Tire Inflation System

The importance of an Automatic Tire Inflation System (ATIS) lies in its ability to address critical
issues related to tire pressure maintenance in vehicles. One of the primary functions of
automotive ATIS is to enhance vehicle safety by ensuring proper tire inflation levels at all times.
Maintaining the correct tire pressure is essential for optimal traction, handling, and braking
performance, especially in adverse driving conditions. ATIS continuously monitors tire pressure
and automatically adjusts inflation levels to compensate for changes in temperature, load, and
driving conditions, reducing the risk of tire blowouts, flats, and accidents caused by
underinflated or overinflated tires.

Moreover, automotive ATIS contributes to improving fuel efficiency and reducing operational
costs for commercial vehicle fleets. Underinflated tires increase rolling resistance, resulting in
higher fuel consumption and premature tire wear. By maintaining optimal tire pressure, ATIS

6
helps to minimize rolling resistance and improve fuel economy, leading to cost savings for fleet
operators and reducing the environmental impact of vehicle operations.

7
Additionally, proper tire inflation extends tire life, reducing replacement frequency and
maintenance expenses. Maintaining optimal tire pressure is essential for several reasons:

1. Safety: Properly inflated tires ensure optimal vehicle handling, stability, and braking
performance, reducing the risk of accidents. Underinflated tires are more prone to
blowouts, loss of control, and increased stopping distances.
2. Fuel Efficiency: Tires operating at the correct pressure reduce rolling resistance,
resulting in improved fuel efficiency and reduced carbon emissions. According to studies,
underinflated tires can decrease fuel efficiency by up to 3% or more.
3. Tire Lifespan: Maintaining the recommended tire pressure extends tire lifespan by
promoting even tread wear and reducing the risk of premature failure. This helps drivers
save money on frequent tire replacements and reduces waste from discarded tires.
4. Environmental Impact: Improved fuel efficiency leads to reduced greenhouse gas
emissions, contributing to environmental sustainability. By minimizing fuel consumption,
ATIS indirectly reduces the carbon footprint of vehicles.
5. Convenience: Manual tire pressure checks and inflation are often neglected or performed
irregularly by drivers. ATIS eliminates the need for manual intervention, ensuring that
tires remain at the optimal pressure level at all times without requiring driver attention.
6. Cost Savings: ATIS helps reduce overall operating costs by improving fuel efficiency,
extending tire lifespan, and minimizing maintenance expenses associated with tire-related
issues.

Additionally, automotive ATIS enhances vehicle uptime and operational efficiency by reducing
downtime associated with manual tire pressure checks and adjustments. With automatic
monitoring and inflation capabilities, ATIS ensures that tire pressure remains within the
recommended range, minimizing the need for manual intervention by drivers or maintenance
personnel. This results in improved vehicle reliability, reduced downtime for tire-related issues,
and increased productivity for commercial vehicle fleets. The automaticTire Inflation System is
crucial for enhancing vehicle safety, fuel efficiency, tire lifespan, and environmental
sustainability while providing convenience and cost savings for vehicle owners. Its

8
implementation represents a proactive approach towards ensuring optimal tire performance and
overall vehicle reliability.

9
 CHAPTER - 2

OBJECTIVES AND SPECIFICATIONS

2.1 Design Objectives

The design objective of the Automatic Tire Inflation System (ATIS) project is to engineer a
sophisticated and dependable system that autonomously monitors and adjusts tire pressure in
vehicles. This system aims to alleviate the need for manual tire pressure checks and inflation,
thereby enhancing vehicle safety, improving fuel efficiency, and prolonging tire lifespan.
Through meticulous design and implementation, the ATIS seeks to seamlessly integrate into
various vehicle types and tire configurations, ensuring compatibility, reliability, and efficiency
across diverse driving conditions. The ultimate goal is to provide drivers with a hassle-free
solution for maintaining optimal tire pressure, contributing to overall vehicle performance and
safety on the road.

2.2 Ability to provide proper tire pressure

The ideal functional objective of our design is its capability to adjust the pressures in all four
tires of a Passenger vehicle to obtain the proper pressure for varying road/driving conditions.
Specifically, it is desired that:
 Cold tire pressure is maintained during vehicle use to account for slow leaks and
Fluctuating tire temperatures.
 As vehicle speed increases, tire pressure increases.
 As vehicle speed decreases, tire pressures decrease.
 As vehicle load increases, tire pressures increase.
 As vehicle load decreases, tire pressures decrease
Based on more detailed research on the components necessary for the system, it was discovered
that a specialized rotary joint must be designed to support this process. This design consideration

10
required additional product development time that was not originally anticipated. Therefore, the
ideal functional objectives have been modified to account for this design requirement.
Specifically, the new objectives require that:
 Cold tire pressure (35 psi) is maintained by ensuring that the rotary joint-shaft system
does not fail structurally.
 Cold tire pressure (35 psi) is maintained by ensuring that the rotary-joint shaft system
does not leak excessively.
 Cold tire pressure (35 psi) is maintained by ensuring that the entire system (compressor,
air tubes, rotary joints, etc.) can provide a sufficient flow rate.
Because of the detailed level of explanation required for these items, these objectives are
described numerically in the Engineering Analysis and Optimization section of this document.

2.3 Minimize Negative Visual Aesthetics

Another design objective is to ensure that the product will not harm current vehicle Aesthetics. It
is imperative that the product seamlessly integrates with the vehicle's design, ensuring that all
components are discreetly positioned and remain inconspicuous during regular operation. The
aim is to create a cohesive visual appearance that enhances rather than detracts from the overall
aesthetic appeal of the vehicle.
To achieve this, careful consideration is given to the placement and design of each component.
The goal is to ensure that components are only visible when necessary, such as during servicing,
and are otherwise hidden from view. This requires meticulous attention to detail in the layout and
packaging of the system, with an emphasis on sleek and unobtrusive design elements.
Of particular concern are the rotary joints, which may be partially visible through the wheel rims.
To minimize their visibility, strategic measures are taken to position the rotary joints in areas
where they are least likely to be noticed, particularly in relation to the brake disks. This involves
analyzing the geometry of the wheel assembly and optimizing the placement of components to
reduce their visual prominence.
To quantify the effectiveness of this design approach, a specific metric is employed. The
"Visible" area of the rotary joint is compared to the "Disk" area of the brake disk, with the
objective of minimizing the former relative to the latter. By minimizing the visible area of the

11
rotary joint in relation to the brake disk, the goal is to create a harmonious visual balance that
preserves the vehicle's aesthetic integrity.

2.4 Ability to Provide Automatic System

The third objective of the project entails the implementation of an automatic system designed to
provide users with all the aforementioned benefits while minimizing their intervention. The
overarching goal is to develop a sophisticated system capable of autonomously adjusting tire
pressures to suit varying road conditions. By integrating advanced sensor technologies and
intelligent algorithms, the system aims to continuously monitor environmental factors such as
temperature, terrain, and road surface conditions.
The envisioned automated system would dynamically respond to changes in driving conditions
by adjusting tire pressures accordingly. For instance, during off-road or rough terrain driving, the
system would automatically increase tire pressures to enhance traction and stability. Conversely,
during highway driving or in wet conditions, tire pressures would be lowered to improve ride
comfort, handling, and braking performance.
However, despite the clear advantages and potential of such an automated tire pressure
adjustment system, its realization within the project timeline poses significant challenges. The
development of robust algorithms capable of accurately interpreting complex environmental data
and dynamically adjusting tire pressures in real-time requires extensive research, testing, and
validation. Additionally, ensuring the seamless integration of this automated functionality with
existing vehicle systems presents technical complexities that cannot be fully addressed within
the project scope.
Given these constraints and the priority placed on achieving the primary objective of maintaining
optimal tire pressure, it has been determined that pursuing the fully automated tire pressure
adjustment system is not feasible at this time. Instead, the project will focus on developing a
reliable and efficient system for monitoring and maintaining tire pressure within preset
parameters, while leaving room for future advancements and enhancements in automated tire
pressure adjustment technology.

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2.5 Low-Cost Device

For both the customer (OEM) and end-user (vehicle owner), it is imperative to keep the price of
the device as low as possible. Considering the potential benefits and cost savings that this design
has to offer and the prices of optional equipment for passenger vehicles with similar complexity,
the target price range for this device has been identified. This is the price for both the OEM and
vehicle owner, assuming that the OEM does not mark up the price. In addition, this price range
should be able to support the costs of components of the system, manufacturing, and any
necessary installation.

2.6 Methodology

After referring to several papers we got many ideas. This system consists of a centralized
compressor, rotary joint, pressure sensor, electronic control circuit, battery, wheel, and a motor
to run that wheel. After getting ideas of the different components needed, we will start making a
rough design and after that, we will draw a 3-D model in Auto CAD. By referring to this 3D
model we will buy the standard component required for the projects. After this, we will start
manufacturing work in the workshop. Along with this electronics part will also be done. In
electronics, we will have to build a controller circuit to get a signal from pressure. Later testing
will be started to get various results.

Figure 2.1 Construction Diagram

13
2.7 Specifications
Table 2.1 Component and Description

Serial No. Description Specification

1 Compressor
2 Rotary Joint
3 Pressure Sensor
4 Bearing
5 Shaft
6 Frame
7 Wheel
8 Hoses
9 DC motor
80psi(5.516bar)12VD.C.
Size=1/2,Pressure=10kg/cm2
Pressure range=0-100 psi
Roller bearing, Carbon Steel
Carbon Steel
75*60*50,Mild Steel
Scooter Wheel
Polyvinylchloride(PVC)
12VDC,100rpm

2.8 Limitations

Automatic tire inflation systems rarely have any disadvantages but there are quite a few:
 As the rotary joint continuously moves its life is limited it needs to be replaced after
some time but with proper maintenance, it can work for a longer duration of time.
 Seals must be replaced regularly for optimum results.
 Pipes and tubes must be inspected from time to time.

14
 CHAPTER-3

LITERATURE SURVEY

3.1 Literature Review

Over a period of 12 weeks in 2013, a trial was conducted involving two cement tankers in NSW,
Australia. For the first 6 weeks, this system was turned on in both tankers, and for another 6
weeks this system was turned off graphs are prepared thatshow that trucks with this system were
in good condition like average vehicle idle time, average vehicle time spent using power take off,
Avg. Emission and fuel combustion.
We also surveyed different people and asked them when they inspect their tire pressure, the
report is as follows:-
 5.40% - 6 Monthly.
 8.10 % - Bi-monthly.
 24.32% - Monthly.
 13.51 % - 5-10 days.
 43.24 % - Weekly.
 5.40% - 3-5 Days.

15
Figure 3.1 Survey report (Pie-chart)

16
The problems they were facing were tire wear, time, and efforts to check as well as fill the
correct air pressure. Also, some unprofessional guys do not fill the correct pressure in the tire
which leads to over-inflation or under-inflation on the tire. To overcome all these our system is
the most suitable also, on summer days, when we drive, the temperature of the tire increases
rapidly, consequently, the heated air inside the tire expands and its pressure rises quickly, which
can lead to a tire blowout with disastrous consequences. So, therefore, to maintain the correct tire
pressure in any weather condition, we must enable this system.

Mark Reiter et, al. The under inflation of pneumatic tires is a typical problem seen in light-duty
vehicles, cars, etc. which affects the vehicle handling characteristics adversely. A lane change
test shows that the required steering wheel angle increased upto 47.7% for front axle tire
inflation pressures at 70% of the nominal values. All tires were inflated to 70% of the
recommended tire pressure when the vehicle slip angle was up to 77.8%. [3] Harshal Junankar et,
al. The paper studies based on air inflation systems are used to maintain tire pressure in the
running condition of vehicles. The environmental conditions change in different seasons because
of this, it is necessary to maintain tire pressure at an optimum level for better performance of the
vehicles. This project deals with the design & fabrication of the automatic tire inflation system
and the study of the effect of pressure variation on tire life.

3.2 History
The concept of a Central Tire Inflation System (CTIS) dates back to the mid-20th century, with
early developments occurring in the military sector. The first known implementation of a CTIS
can be traced back to the 1950s and 1960s, primarily in military vehicles such as armored
personnel carriers and tanks.

One notable example is the M561 "Gama Goat," a six-wheel drive off-road vehicle used by the
United States military during the Vietnam War era. The Gama Goat featured a pneumatic CTIS
that allowed the driver to adjust tire pressure on the fly to optimize traction and performance
over various terrains.

While these early implementations were primarily confined to military applications, CTIS
technology has since evolved and found its way into commercial off-road vehicles, agricultural

17
machinery, and even some high-end consumer vehicles. Today, CTIS is widely recognized for its
ability to enhance vehicle mobility, performance, and safety across diverse terrain conditions

3.2.1 Michelin's Use of Central Tire Inflation Systems (CTIS) for Agricultural Purposes

Michelin, a global leader in tire manufacturing, has been at the forefront of developing
innovative solutions to meet the evolving needs of the agricultural industry. One such solution is
the integration of Central Tire Inflation Systems (CTIS) into agricultural tires, aimed at
optimizing performance and productivity in farming operations.

Several studies and reports have highlighted the benefits of Michelin's CTIS technology in
agricultural applications:

1. Improved Traction and Soil Compaction Management: Research conducted by

Michelin and various agricultural institutes has demonstrated that CTIS-equipped tires
offer superior traction and soil compaction management compared to conventional tires.
By adjusting tire pressure to match specific field conditions, farmers can minimize soil
compaction, preserve soil structure, and enhance crop yields.
2. Enhanced Fuel Efficiency and Operational Flexibility: Studies have shown that CTIS-
equipped agricultural vehicles experience improved fuel efficiency due to reduced rolling
resistance and optimized traction. Additionally, the ability to adjust tire pressure on the
go allows farmers to adapt to changing terrain and weather conditions, maximizing
operational flexibility and productivity.
3. Reduced Environmental Impact: Michelin's CTIS technology contributes to
sustainable agricultural practices by minimizing soil compaction and reducing fuel
consumption. These environmental benefits align with global initiatives to promote
sustainable farming methods and mitigate the environmental impact of agricultural
activities.
4. Field Trials and User Feedback: Field trials conducted by Michelin and agricultural
machinery manufacturers have yielded positive feedback from users regarding the
performance and reliability of CTIS-equipped tires. Farmers have reported increased

18
 operational efficiency, reduced downtime, and improved overall satisfaction with the
technology.
5. Continued Innovation and Product Development: Michelin remains committed to
advancing CTIS technology for agricultural purposes through ongoing research,
development, and collaboration with industry partners. Continued innovation in tire
design, sensor technology, and integration with precision agriculture systems is expected
to further enhance the capabilities and benefits of CTIS-equipped tires in the future.

In conclusion, Michelin's utilization of Central Tire Inflation Systems (CTIS) for agricultural
purposes represents a significant advancement in tire technology aimed at improving
performance, productivity, and sustainability in farming operations. The growing body of
literature and field experience underscores the value of CTIS-equipped tires as a versatile
solution for addressing the evolving needs of modern agriculture.

19
 CHAPTER - 4

HARDWARE DESCRIPTION

4.1 Layout of Tire Inflation System

Fig 4.1 Tire Inflation System Configuration

4.2 Portable Compressor

The 12V Car Electric Air Compressor Tire Pump is a versatile and convenient tool for inflating
car tires, as well as tires for bikes, cycles, and even boats, along with inflatable toys. This brand-
new 12V air compressor offers fast and easy inflation without the need for manual pumping.
Powered directly from your car's battery, it requires no physical exertion, making it perfect for
anyone looking for effortless tire inflation.

Compared to traditional mechanical pumps, this compressor saves time with its quick operation
and compact design. It's easy to store in your car's trunk or toolbox, ensuring accessibility
whenever you need it. Whether you're inflating auto tires, car or bike tires, rubber rafts, or sports

20
equipment like basketballs and soccer balls, this compressor gets the job done swiftly and
efficiently. Moreover, it's versatile enough to inflate boats, pools, air beds, balloons, and more,
offering a comprehensive solution for various inflation tasks. With its user-friendly design and
time-saving benefits, the 12V Car Electric Air Compressor Tire Pump is the ideal choice for
anyone seeking convenience and ease while inflating tires or other inflatable items.

Fig. 4.2 12V Car Electric Air Compressor

4.3 Solenoid Valves (In Future)

The 2/2 air solenoid valves are direct-acting solenoid valves that operate without requiring a
minimum operating differential pressure. As illustrated below, when the coil is energized (as
depicted in the right diagram), it lifts the solenoid plunger from its resting position on the valve
seat, thus opening the main valve orifice. Conversely, when the coil is de-energized (as shown in
the right diagram), the spring exerts force on the plunger, causing it to return to its original
position on the valve seat. This action effectively closes the valve orifice.

In practical terms, this means that the valve can be controlled electronically to allow or restrict
the flow of air without relying on the presence of a certain pressure difference. When the coil is
powered, the valve opens to permit the passage of air, and when the coil is not energized, the
valve closes to block the flow of air. This direct-acting mechanism ensures reliable and efficient

21
operation of the solenoid valve, making it suitable for various applications where precise control
of airflow is required.

22
 Fig. 4.3 The 2/2 Solenoid Valves

4.4 Pressure Sensor (In Future)

A pressure sensor is an instrument designed to measure pressure, typically of gases or liquids.
Pressure, in this context, refers to the force required to halt the expansion of a fluid, and it is
commonly expressed as force per unit area. Essentially, a pressure sensor functions as a
transducer, converting the pressure it detects into an electrical signal.
These sensors find widespread use in countless everyday applications for control and monitoring
purposes. They play crucial roles in various industries and sectors, from automotive and
aerospace to healthcare and manufacturing. Beyond directly measuring pressure, these sensors
can also indirectly gauge other variables such as fluid or gas flow, velocity, water level, and
altitude.

23
Fig. 4.4 The inbuilt tire pressure sensor

24
Moreover, pressure sensors are known by various names, including pressure transducers,
pressure transmitters, pressure senders, pressure indicators, piezometers, and manometers,
among others. This diversity in nomenclature reflects the wide range of applications and contexts
in which these sensors are employed.

In terms of technology and design, pressure sensors can vary significantly, leading to differences
in performance, suitability for specific applications, and cost. It's estimated that there are over 50
distinct technologies used in pressure sensor manufacturing, with at least 300 companies
worldwide involved in their production.
This diversity underscores the importance and versatility of pressure sensors in modern
technology and industry, where their precision and reliability contribute to the smooth operation
of countless systems and processes.

4.5 Rotary Joint

In the process of designing a device for common passenger vehicles, we encountered a
significant challenge posed by the presence of the axle shaft, which runs directly into the center
of the wheel. This obstacle necessitated the exploration of alternative methods for routing air to
the intended destination.
Our proposed solution to this challenge involves the incorporation of a rotary joint into the
design. This rotary joint comprises two halves: one half that rotates with the drive axle hub and
another half that remains stationary with the spindle. Within this rotary joint, we plan to integrate
an air chamber that facilitates the passage of air from the stationary half of the joint to the
rotating half.
By implementing this rotary joint with an integrated air chamber, we aim to overcome the
obstacle presented by the axle shaft while ensuring the efficient and effective routing of air to its
intended destination. This solution enables us to maintain the functionality and performance of
the device within the constraints imposed by the vehicle's structure and components.

25
 Fig. 4.5 (A) The cross-sectional View of the Rotary Joint.

Fig. 4.5 (B) The labeled diagram of the Rotary Joint.

The main criteria for our rotary joint design were the following:
 Must have approx. 40mm hole in the center to allow for the axle to either pass through or
support the joint.
 Air inlets and outlets must be located at the outer radius to allow the hoses on the outside
of the joint to clear the vehicle spindle and hub.
 Overall thickness of the joint must be no greater than 25mm so as not to interfere with the

26
 vehicle driveline or suspension components.
 A ball bearing system must be used to reduce contact friction between the two rotating
halves both axial and planar.

4.6 Pressure Switch

A pressure switch used in automotive applications is a device that monitors the pressure of a
fluid or air within a system and triggers a response when the pressure reaches a certain threshold.
This switch typically consists of a sensing element that detects pressure changes and a
mechanism to actuate a switch or relay.

In this project, the pressure switch plays a crucial role in the automatic tire inflation system. It
serves as a key component for monitoring the air pressure within the vehicle's tires. When the
tire pressure falls below a predetermined level, the pressure switch detects this decrease and
activates the air compressor to inflate the tire to the desired pressure.

By incorporating a pressure switch into the system, we ensure that the tires are maintained at
optimal pressure levels automatically, enhancing safety, performance, and fuel efficiency. This
switch provides real-time monitoring and control, allowing for timely intervention to prevent
under inflation or over inflation of the tires.

Fig. 4.6 The Pressure Switch.

27
4.7 Car Battery 12 V
The automotive car battery utilized in this project serves as the primary power source for running
various components, including a 12V DC motor, a 12V air compressor, tire pressure sensors,
solenoid valves, and other associated devices.
To accommodate the power requirements of the project, the car battery must have a sufficient
capacity and voltage rating to support the continuous operation of these components. Typically,
automotive batteries are designed to deliver ample power for starting the vehicle's engine and
powering onboard electronics.
In this application, the car battery supplies power to the 12V DC motor, which operates at 2750
revolutions per minute (rpm) and has a power rating of 240 watts. Additionally, the battery
powers the 12V air compressor used for tire inflation, along with the tire pressure sensors and
solenoid valves responsible for controlling airflow within the system.
It's essential to ensure that the automotive battery selected for the project has the necessary
capacity and output capabilities to sustain the simultaneous operation of these devices without
experiencing significant voltage drops or depletion of power. Proper battery sizing and
maintenance are crucial to ensure reliable performance and longevity of the system.

Fig. 4.7 The 12V Car Battery.

28
4.8 Central Tire Inflation System (CTIS) ( In Future)

The idea behind the CTIS is to provide control over the air pressure in each tire as a way to
improve performance on different surfaces. For example, lowering the air pressure in a tire
creates a larger area of contact between the tire and the ground and makes driving on softer
ground much easier. It also does less damage to the surface. This is important on work sites and
in agricultural fields. By giving the driver direct control over the air pressure in each tire,
maneuverability is greatly improved. Another function of the CTIS is to maintain pressure in the
tires if there is a slow leak or puncture.

In this case, the system controls inflation automatically based on the selected pressure the driver
has set. There are two main manufacturers of the CTIS: U.S.-based Dana Corporation and
France-based Syegon (a division of GIAT). Dana Corporation has two versions, the CTIS for
military use (developed by PSI) and the Tire Pressure Control System (TPCS) for commercial,
heavy machinery use. In the next section, we'll take a look at the inner workings of a basic CTIS
setup.

29
Fig. 4.8 Central Tire Inflation System (CTIS).

30
The wheel valve, situated at each wheel end, plays a pivotal role in the central tire inflation
system (CTIS) implementation. In the case of dual wheels, these valves are typically linked
solely to the outer wheel to facilitate pressure balancing between the paired tires. Additionally,
the wheel valve functions to isolate the tire from the system during periods of inactivity, thus
relieving pressure on the seal and prolonging its operational lifespan. Moreover, it enables on-
demand tire inflation and deflation, ensuring optimal tire pressure based on driving conditions.

Central to the CTIS operation is the electronic control unit (ECU), positioned behind the
passenger seat, serving as the system's control hub. The ECU processes driver commands,
monitors signals across the system, and periodically checks tire pressures to ensure the selected
pressure level is maintained. It communicates commands to the pneumatic control unit, which
directly manages the wheel valves and air system. Within the pneumatic control unit lies a sensor
responsible for transmitting tire pressure readings back to the ECU.

An operator control panel, mounted on the dashboard, provides the driver with interface options
to select tire-pressure modes tailored to prevailing conditions. This panel displays real-time tire
pressures, selected modes, and system status. Upon selecting a tire pressure setting, signals
traverse from the control panel to the ECU, then to the pneumatic control unit, and ultimately to
the wheel valves for adjustment.

Dynamic adjustments to tire pressure are facilitated by a speed sensor integrated into the system.
As vehicle speed increases, indicating highway driving, the speed sensor relays this information
to the ECU. If sustained high speeds are detected, the system autonomously inflates the tires to a
pressure suitable for such conditions, mitigating potential tire damage.

In terms of pneumatic supply, the CTIS harnesses air from the same compressor responsible for
supplying air to the brake system. However, a pressure switch ensures that the brake system
takes precedence, preventing the CTIS from drawing air from the supply tank until the brake
system is fully pressurized. This design prioritizes safety and operational integrity by ensuring
adequate braking capability at all times.

31
 CHAPTER - 5

MATERIAL SELECTION AND DETAILS

5.1 Material Selection

The proper selection of material for the different parts of a machine is the main objective in the
fabrication of the machine. For a design engineer, it is a must that is familiar with the effect, that
the manufacturing process and heat treatment have on the properties of materials.
The Choice of material for engineering purposes depends upon the following factors:
1. Availability of the materials.
2. Suitability of materials for the working conditions in service.
3. The cost of materials.
4. Physical and chemical properties of material.
5. Mechanical properties of material.
The mechanical properties of the metals are those, which are associated with the ability of the
material to resist mechanical forces and load. We shall now discuss these properties as follows:
1. Strength: A material can resist externally applied forces.
2. Stress: Without breaking or yielding. The internal resistance offered by a part to an
externally applied force is called stress.
3. Stiffness: Material can resist deformation under stresses. The modules of elasticity of the
measure of stiffness.
4. Elasticity: It is the property of a material to regain its original shape after deformation
when the external forces are removed. This property is desirable for materials used in
tools and machines. It may be noted that steel is more elastic than rubber.
5. Plasticity: It is the property of a material, thatretains the deformation produced under load
permanently. This property of the material is necessary for forging, stamping images on
coins, and in ornamental work.

32
6. Ductility: It is the property of a material enabling it to be drawn into wire with the
application of a tensile force. A ductile material must be both strong and plastic.

33
 The ductility is usually measured by the terms, percentage elongation and percent
reduction in area. The ductile materials commonly used in engineering practice are mild
steel, copper, aluminum, nickel, zinc, tin, and lead.
7. Brittleness: It is the property of material opposite to ductile. It is the property of breaking
a material with little permanent distortion. Brittle materials when subjected to tensile
loads snap off without giving any sensible elongation. Cast iron is a brittle material.
8. Malleability: It is a special case of ductility, which permits material to be rolled or
hammered into thin sheets, a malleable material should be plastic but it is not essential to
be so strong. The malleable materials commonly used in engineering practice are lead,
soft steel, wrought iron, copper, and aluminum.
9. Toughness: It is the property of a material to resist fracture due to high-impact loads like
hammer blows. The toughness of the material decreases when it is heated. It is measured
by the amount absorbed after being stressed up to the point of fracture. This property is
desirable in parts subjected to shock and impact loads.
10. Resilience: It is the property of a material to absorb energy and resist rock and impact
loads. It is measured by the amount of energy absorbed per unit volume within the elastic
limit. This property is essential for spring material.
11. Creep: When a part is subjected to constant stress at high temperatures for a long period,
it will undergo a slow and permanent deformation called creep. This property is
considered in designing internal combustion engines, boilers, and turbines.
12. Hardness: It is a very important property of metals and has a wide variety of meanings. It
embraces many different properties such as resistance to wear scratching, deformation
machine ability, etc. It also means the ability of the metal to cut another metal. The
hardness is usually expressed in numbers, which are dependent on the method of making
the test.
The hardness of a metal may be determined by the following test.
a) Brinell hardness test
b) Rockwell hardness test
c) Vickers hardness (also called diamond pyramid) test and
d) Share scaleroscope.

34
The science of the metal is specialized and although it overflows into realms of knowledge it
tends to shut away from the general reader. The knowledge of materials and their properties is of
great significance for a design engineer. The machine elements should be made of such a
material that has properties suitable for the conditions of operations. In addition to this a design
engineer must be familiar with the manufacturing processes and the heat treatments have on the
properties of the materials.
In designing the various parts of the machine it is necessary to know how the material will
function in service. For this certain characteristics or mechanical properties mostly used in
mechanical engineering practice are commonly determined from standard tensile tests. In
engineering practice, the machine parts are subjected to various forces, which may be due to
either one or more of the following.
1. Energy transmitted
2. Weight of machine
3. Frictional resistance
4. Inertia of reciprocating parts
5. Change of temperature
6. Lack of balance of moving parts
The selection of the materials depends upon the various types of stresses that are set up during
operation. The material selected should withstand it. Other criteria for the selection of metal
depend upon the type of load because a machine part resists load more easily than a live load and
live load more easily than a shock load.
Selection of the material depends upon the factor of safety, which in turn depends upon the
following factors.
1. Reliabilities of properties
2. Reliability of applied load
3. The certainty as to the exact mode of failure
4. The extent of simplifying assumptions
5. The extent of localized
6. The extent of initial stresses set up during manufacturing
7. The extent of loss of life if failure occurs
8. The extent of loss of property if a failure occurs.

35
9. Materials selected in m/c
10. Base plate, motor support, sleeve and shaft
11. Material used
Mild steel
Reasons:
1. Mild steel is readily available in the market
2. It is economical to use
3. It is available in standard sizes
4. It has good mechanical properties i.e. it is easily machine able
5. It has a moderate factor of safety because the factor of safety results in unnecessary wastage
of material and heavy selection. The low factor of safety results in an unnecessary risk of
failure
6. It has a high tensile strength
7. Low coefficient of thermal expansion
Properties of Mild Steel:
M.S. has a carbon content of 0.15% to 0.30%. They are easily wieldable and thus can be
hardened only. They are similar to wrought iron in properties. Both the ultimate tensile and
compressive strength of these steel increases with increasing carbon content. They can be easily
gas welded or electric or arc welded. With the increase in the carbon percentage, weldability
decreases. Mild steel serves the purpose and was hence selected because of the above purpose.

5.2 Bright Material

The fundamental distinction between mild steel and bright metal lies in their manufacturing
processes. While mild steel plates and bars are typically hot forged using forging machines,
bright metal undergoes a drawing process wherein materials are drawn from dies in a plastic
state. As a result of this method, bright metal exhibits a superior surface finish compared to mild
steel, devoid of any carbon deposits that may arise during the extrusion and formation of
engineering materials. This characteristic not only enhances the surface quality but also
preserves the inherent metallic properties of the material.

36
5.3 Raw and Standard Material

Table 5.1 Specification

SR NO PART NAME MAT QTY

1 FRAME MS 25 KG

2 CHAIN DRIVE 6.25” PITCH STD 1 SET

3 SHAFT DIA 20 MM MS 1NOS

4 017 WATT DC MOTOR MS 1 NOS

5 CONTROLLING CKT (IN THE FUTURE) STD 1 NOS

6 WHEEL STD 1NOS

7 BATTERY RU 1 NOS

8 COMPRESSER STD 1NOS

9 ROTARY VALVE STD 1 NOS

10 PRESSURE GAUGE STD 1 NOS

11 PEDESTAL BEARING P204 2 NOS

12 NUT BOLT WASHER M 10 MS 8 NOS

13 WELDING ROD - 1 50 NOS

37
14 RED OXID - 1 LIT

38
 CHAPTER - 6

MACHINE DESIGN

6.1 Introduction

This chapter describes some of the mathematical techniques used by designers of complex
structures. Mathematical models and analysis are briefly described and a detailed description is
given of the finite–element method of structural analysis. Solution techniques are presented for
static, dynamic & model analysis problems. As part of the design procedure, the designer must
analyze the entire structure and some of its components.
To perform this analysis the designer will develop mathematical models of structure that are
approximations of the real structure, these models are used to determine the important
parameters in the design. The type of structural model the designer uses depends on the
information that is needed and the type of analysis the designer can perform.
Three types of structural models are:
1. Rigid Members: The entire structure or parts of the structure are considered to be rigid;
hence no deformation can occur in these members.
2. Flexible members: The entire structure or parts of the structure are modeled by members
that can deform but in limited ways. Examples of these members are trusses, beams, and
plates.
3. Continuum: A continuum model of structure is the most general, since few if any
mathematical assumptions about the behavior of the structure need to be made before
making a continuum model. A continuum member is based on the full three–dimensional
equations of continuum models. In selecting a model of the structure.
The designer also must consider the type of analysis to be performed. Four typical analyses that
designers perform are:
1. Static equilibrium: In this analysis, the designer is trying to determine the overall forces
and moments that the design will undergo. The analysis is usually done with rigid
members of the model of structure and is the simplest analysis to perform.

39
 2. Deformation: This analysis is concerned with how much the structure will move when
operating under the design loads. This analysis is usually done with flexible members.
3. Stress: In this analysis, the designers want a very detailed picture of where and at what
level the stresses are in the design. This analysis is usually done with continuum
members.
4. Frequency: This analysis is concerned with determining the natural frequencies and
made shape of a structure. This analysis can be done with either flexible members of a
structure. This analysis can be done with either flexible members or continuum members
but now the mass of the members is included inthe analysis.
The subject of MACHINE DESIGN deals with the art of designing machines of structure. A
machine is a combination of resistance bodies with successfully constrained relative motions that
are used for transforming other forms of energy into mechanical energy or transmitting and
modifying available designs to create new and better machines or structures and improving the
existing ones such that it will convert and control motions either with or without transmitting
power. It is the practical application of machinery to the design and construction of machines and
structures.
To design simple components satisfactorily, a sound knowledge of applied science is essential.
In addition, the strength and properties of materials including some metrological are of prime
importance. Knowledge of the theory of machines and other branches of applied mechanics is
also required to know the velocity. Acceleration and inertia force of the various links in motion,
and mechanics of machinery involve the design.

6.2 Concept in M.D.P.

Consideration in Machine Design

When a machine is to be designed the following points are to be considered: -
i) Types of load and stresses caused by the load.
ii) Motion of the parts and kinematics of the machine. This deals with the
type of motion i.e. reciprocating. Rotary and oscillatory.
iii) Selection of material & factors like strength, durability, weight,
Corrosion resistance, weldability, and machine ability are considered.

40
 iv) Form and size of the components.
v) Frictional resistance and ease of lubrication.
vi) Convince and economical in operation.
vii) Use of standard parts.
viii) Facilities available for manufacturing.
ix) Cost of making the machine.
x) Numbers of machines or products are manufactured.

6.3 General Procedure in Machine Design

The general steps to be followed in designing the machine are as follows.
i) Preparation of a statement of the problem indicating the purpose of the machine.
ii) Selection of groups of mechanisms for the desired motion.
iii) Calculation of the force and energy on each machine member.
iv) Selection of material.
v) Determining the size of the component drawing and sending it for manufacturing
vi) Preparation of component drawing and sending for manufacture.
vii) Manufacturing and assembling the machine.
viii) Testing of the machine and for functioning.

6.4 Calculations
Power of Shaft = P = 17 watt
Power transmitted by shaft,
2πNT
P = -----------------
60
Where,
N→ Rpm of motor shaft = 24

T →Torque transmitted
2π x 24 x T

41
17 = ---------------------- x 103
60
T= 6.76 x 103 N-mm
We know that,
No. of teeth (Gear), N1 = 12
No. of teeth (sprocket), N2 = 36
Ratio = R = 1 : 3
Torque on sprocket = 3 × T
= 3 × 6.76 x 103
= 20.280 x 103 N-mm
Torque transmitted,
T = Force × radius
20.280 x 103 = F× 36
F = 563.33N
F = 563.33 N
-----------------
9.81
F = 58 Kg

Torque transmitted by shaft,

T = π/16 x τ x d3
Select permissible shear stress (τ) from the design data book.
τ = 70 N/mm2
Therefore, 20.28 x 103 = π /16 x d3 x 70
D = 12 mm.

Taking Factor Of Safety = 1.6

D actual = 12 x 1.6 = 19.2 mm
We select dia. Of shaft = 20 mm.
For the 20 mm shaft dia, we select standard PEDESTAL BEARING P204.

42
 CHAPTER - 7

COST ESTIMATION SOFTWARE DESCRIPTION

Cost estimation is the meticulous and systematic process of forecasting the anticipated expenses
that must be incurred throughout the entirety of a product's manufacturing lifecycle. This process
involves a comprehensive evaluation of all financial outlays, encompassing both the design and
manufacturing phases.
Within the realm of manufacturing, cost estimation extends beyond the direct costs of materials
and labor to include various ancillary expenses. These may include expenditures related to
essential services and facilities such as pattern-making and tool manufacturing. Furthermore, a
portion of general administrative and selling costs is factored into the estimation to ensure a
holistic view of the financial requirements.
By diligently analyzing and quantifying these various cost components, cost estimation provides
a clear understanding of the financial implications associated with bringing a product to market.
It serves as a vital tool for decision-making, enabling stakeholders to make informed choices
regarding resource allocation, pricing strategies, and overall project feasibility.
Ultimately, an accurate and thorough cost estimation process is essential for ensuring the
financial viability and success of a manufacturing project. It lays the foundation for effective
budgeting, resource management, and strategic planning, thereby facilitating the achievement of
project objectives within predefined financial constraints.

7.1 Purpose of Cost Estimating

1. To determine the selling price of a product for a quotation or contract to ensure a reasonable
profit to the company.
2. Check the quotation supplied by vendors.
3. Determine the most economical process or material to manufacture the product.
4. To determine standards of production performance that may be used to control the cost.

43
 5. Cost estimating helps in forecasting the financial outcomes of a project, allowing companies
to anticipate potential revenue streams, cash flows, and profitability over the project
lifecycle.
6. Cost estimating aids in resource planning by identifying the quantity and types of resources
required for project execution, including materials, labor, equipment, and facilities.
7. Cost estimating is crucial for preparing competitive bids in response to requests for
proposals (RFPs) or tender invitations, enabling companies to accurately price their
offerings and increase their chances of winning contracts.

7.2 Material Cost Estimation

Material cost estimation involves determining the total expenditure necessary to procure the raw
materials essential for the fabrication or processing of components to meet desired specifications
and functionality. This process entails a thorough assessment of the financial outlay associated
with acquiring the requisite raw materials required for the project. By accurately quantifying
these material costs, stakeholders gain insight into the financial requirements for sourcing and
processing materials, facilitating effective budgeting and resource allocation throughout the
project lifecycle.
These materials are divided into two categories.
 Material for fabrication:
In this, the material is obtained in raw condition and is manufactured or processed to a finished
size for the proper functioning of the component.
 Standard purchased parts:
This includes the parts which were readily available in the market like Allen screws etc. A list is
forecast by the estimation stating the quality, size, and standard parts, the weight of raw material,
and cost per kg. for the fabricated parts.

7.3 Machining Cost Estimation

Cost estimation for manufactured parts involves the systematic prediction of total expenses
incurred beyond material costs. It constitutes a deliberate assessment, incorporating factors such

44
as labor, materials, and factory services essential for the production of the specified part. This
process entails meticulous judgment and thorough consideration to accurately forecast the
comprehensive expenses associated with manufacturing operations. By encompassing a holistic
view of the production process, including labor, materials, and overhead costs, cost estimation
enables informed decision-making and effective resource allocation throughout the
manufacturing lifecycle.

7.4 Procedure for Calculation of Material Cost

The material cost estimation process follows a structured procedure, typically initiated after
project design. The first step involves preparing a bill of materials (BOM), which categorizes
components into two main groups: fabricated components and standard purchased components.
For standard purchased components, rates are obtained and totaled based on established pricing
structures. This includes sourcing costs for off-the-shelf items such as parts, components, or
assemblies procured from external suppliers.
Simultaneously, the cost of raw materials purchased for fabricating components is determined
and aggregated. This entails assessing the cost of acquiring raw materials needed for in-house
manufacturing processes, considering factors such as material type, quantity, and market prices.
Upon completion of these assessments, the total material cost estimation is obtained by summing
the costs of standard purchased components and raw materials purchased for fabrication. This
systematic approach ensures a comprehensive evaluation of material expenses, providing a basis
for accurate project budgeting and resource allocation.

7.5 Labour Cost

Labor cost refers to the expenditure incurred on remunerating employees within an organization,
encompassing wages, salaries, commissions, bonuses, and related compensations.
Labor costs can be categorized into two main classifications:
1. Direct Labour Cost:
Direct labor cost pertains to the remuneration of employees directly involved in the
manufacturing process, whose efforts can be directly attributed to the production of goods or

45
services. These employees directly contribute to the transformation of raw materials into finished
products. Direct labor costs are allocated to specific cost centers or cost units within the
organization. This allocation can be based on various factors, including the time spent by
workers on specific tasks or the physical output achieved. Direct labor costs play a crucial role in
determining the unit cost of production or the cost of individual jobs. They are essential for
accurately assessing the expenses associated with producing goods or services and are integral to
cost accounting and cost management practices within the enterprise.
2. Indirect labor cost:
Indirect labor cost encompasses the expenditure associated with labor that cannot be directly
attributed to specific tasks but can be distributed among various cost centers or units within the
organization. This category of labor expense comprises activities that facilitate the progressive
movement and handling of products without directly impacting their construction, composition,
or condition.
Examples of roles incurring indirect labor costs include maintenance personnel, helpers, machine
setters, supervisors, and foremen. While these roles are essential for overseeing operations and
ensuring the smooth flow of production, their contributions do not directly alter the physical
characteristics of the final product.
The calculation of total labor cost typically involves assessing the wages paid to labor based on a
standard workday, commonly assumed to be 8 hours per day. This calculation provides a
comprehensive overview of the overall labor expenditure incurred by the organization,
encompassing both direct and indirect labor costs.
 Cost estimation is done under
Cost of project = (A) material cost + (B) Machining cost + (C) labour cost
(A)Material cost is calculated as under: -
i) Raw material cost
ii) Finished product cost
i) Raw material cost
It includes the material in the form of the Material supplied by the “ Steel Authority of India
Limited” and ‘Indian Aluminum Co.,’ as the round bars, angles, square rods, and plates along
with the strip material form. We have to search for the suitable available material as per the
requirement of designed safe values.

46
We have searched the material as follows: -

7.6 Raw Material & Standard Material

Table 7.1 Material used
SR NO PART NAME MAT QTY COST

1 FRAME MS 25 KG 3000

2 SHAFT DIA 20 MM MS 1NOS 650

3 240 -WATT DC MOTOR MS 1 NOS 1700

4 WHEEL STD 1NOS 2200

5 BATTERY RU 1 NOS 1500

6 COMPRESSER STD 1NOS 1000

7 ROTARY VALVE STD 1 NOS 2800

8 PRESSURE GAUGE STD 1 NOS 450

9 PEDESTAL BEARING P204 2 NOS 700

10 NUT BOLT WASHER M 10 MS 8 NOS 120

11 WELDING ROD - 1 50 NOS 150

12 RED OXID - 1 LIT 200

13 MISCELLANEOUS 3000

TOTAL

47
7.7 Software Description

 FLOW CHART

 Methodology
In the tire inflation system, compressed air is supplied to the inlet of the 2/2 solenoid valve. A
pressure switch is employed to monitor the tire pressure, with the desired pressure level set by
the pressure switch reading. This switch detects the current tire pressure and sends an output
signal to the solenoid valve.
When the tire pressure falls below the set threshold, the pressure switch activates the solenoid
valve, allowing compressed air to flow into the tire through a quick-release coupling. This
coupling facilitates the free rotation of the wheel while enabling efficient air transfer.
Once the tire reaches the desired pressure level, the pressure switch deactivates the solenoid
valve, ensuring that the tire pressure remains constant and within the specified range. This
automated process ensures optimal tire inflation and maintenance, enhancing vehicle
performance and safety.

48
 CHAPTER - 8

ADVANTAGES AND FUTURE SCOPE

8.1 Advantages
The dynamically self-inflating tire system would be capable of succeeding as a new product in
the automotive supplier industry. It specifically addresses the needs of the consumers by
maintaining appropriate tire pressure conditions for:
 Reduced tire wear
 Increased fuel economy
 Increased overall vehicle safety
Because such a product does not currently exist for the majority of passenger vehicles, the
market conditions would be favorable for the introduction of a self-inflating tire system.
Through extensive engineering analysis, it has also been determined that the self-inflating tire
system would function as desired. In particular, the product would be capable of:
 Providing sufficient airflow to the tire with minimal leakage.
 Withstanding the static and dynamic loading exerted on the rotary joints,
Note that likewise, this system would not produce any negative dynamic effects (such as CV
joint failure due to resonance) on surrounding systems. Most significantly, the self-inflating tire
system would be a successful product because of its economic benefits to investors. Specifically,
the final product would:
 Sell at about $450/unit, with total first-year profit and sales of nearly $2.1 million and
58,000 units, respectively.
 Experience 12% annual market growth each year for the first five years of the product,
bringing total sales up to 370,000 units.
 Break even on the capital investment in just under three years For further development of
this product,
we recommend increasing the capability of the system by adding the following features:
 Pressure adjustment based on increasing vehicle speed.

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  Pressure adjustment based on increasing vehicle load.
 Adaptability for recreational use (inflating rafts, sports balls, etc.)
 Implementation of interactive display.
 Creation of universal design for aftermarket use.

8.2 Future Scope

The advancement of automatic tire inflation systems presents promising prospects for the
automotive industry and vehicle owners alike. While initial investment costs may be incurred,
the long-term benefits are substantial, primarily for vehicle owners.
Implementing this technology enables adjustments to tire pressure based on driving conditions,
leading to reduced tire wear and enhanced fuel economy. These advantages translate into
significant cost savings for vehicle owners over time.
Beyond individual vehicle owners, society stands to gain from the widespread adoption of
automatic tire inflation systems. The reduction in tire disposal in landfills and decreased
consumption of natural resources contribute to environmental sustainability. Additionally, the
improvement in vehicle safety benefits all individuals who utilize roadways.
However, it's important to acknowledge that not all sectors will benefit equally from this
technological advancement. Tire manufacturers may experience a decrease in demand for their
products as tires last longer and require fewer replacements due to reduced wear. Similarly, the
petroleum industry may see a decline in demand for oil, given the increase in fuel economy
achieved through this technology.
Despite potential challenges for certain industries, the overall societal and environmental benefits
of automatic tire inflation systems are significant. As technology continues to evolve, the
automotive industry will likely witness further innovations aimed at enhancing vehicle
performance, safety, and sustainability.
The advancement of automatic tire inflation systems presents promising prospects for the
automotive industry and vehicle owners alike. Research indicates that widespread adoption of
this technology could revolutionize the way vehicles maintain tire pressure, leading to various
benefits beyond what has been previously mentioned.
One significant advantage highlighted by recent studies is the potential for automatic tire

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inflation systems to improve overall vehicle performance and handling. By ensuring that tires are
consistently inflated to optimal levels, these systems can enhance traction, stability, and
maneuverability, particularly in adverse weather conditions or challenging terrain. This
improvement in vehicle dynamics not only enhances safety but also enhances the driving
experience for vehicle owners.
Furthermore, research suggests that the integration of automatic tire inflation systems with
emerging technologies such as vehicle-to-vehicle communication and autonomous driving
systems could unlock even greater benefits. These synergistic approaches can enable real-time
monitoring and adjustment of tire pressure based on dynamic factors such as road conditions,
traffic patterns, and vehicle load. This level of adaptability and responsiveness could further
optimize fuel efficiency, reduce emissions, and minimize the risk of accidents.
While the initial investment costs for implementing automatic tire inflation systems may be a
concern for some stakeholders, studies indicate that the long-term economic and environmental
benefits far outweigh these upfront expenses. By extending the lifespan of tires, reducing fuel
consumption, and minimizing the need for tire replacements and maintenance, these systems
offer significant cost savings and contribute to sustainability goals.
The future scope of automatic tire inflation systems is vast and multifaceted. As research and
development efforts advance, we can expect to see more innovations in this field that enhance
vehicle performance, safety, and sustainability, benefiting both individual vehicle owners and
society.

8.3 Automotive Automatic Tire Inflation System Market Value, Trends

[2029], Economy, Expansion, Leader
According to TechSci Research report, “Automotive Automatic Tire Inflation System Market –
Global Industry Size, Share, Trends, Competition Forecast & Opportunities, 2029”, the Global
Automotive Automatic Tire Inflation System Market stood at USD 266.71 Million in 2023 and is
anticipated to grow with a CAGR of 7.44% in the forecast period, 2025-2029. The automotive
automatic tire inflation system (ATIS) market represents a crucial advancement in vehicle safety
and efficiency, offering a proactive solution to maintain optimal tire pressure while the vehicle is
in operation. ATIS is designed to automatically monitor, inflate, and deflate tire pressure to the
manufacturer's recommended specifications, ensuring consistent and safe tire performance on the

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road. This technology is particularly beneficial for commercial vehicles, such as trucks, buses,
and military vehicles, where tire maintenance is critical for operational efficiency and safety.
One of the primary functions of automotive ATIS is to enhance vehicle safety by ensuring proper
tire inflation levels at all times. Maintaining the correct tire pressure is essential for optimal
traction, handling, and braking performance, especially in adverse driving conditions. ATIS
continuously monitors tire pressure and automatically adjusts inflation levels to compensate for
changes in temperature, load, and driving conditions, reducing the risk of tire blowouts, flats, and
accidents caused by underinflated or overinflated tires.
Moreover, automotive ATIS contributes to improving fuel efficiency and reducing operational
costs for commercial vehicle fleets. Underinflated tires increase rolling resistance, resulting in
higher fuel consumption and premature tire wear. By maintaining optimal tire pressure, ATIS
helps to minimize rolling resistance and improve fuel economy, leading to cost savings for fleet
operators and reducing the environmental impact of vehicle operations. Additionally, proper tire
inflation extends tire life, reducing replacement frequency and maintenance expenses.
Additionally, automotive ATIS enhances vehicle uptime and operational efficiency by reducing
downtime associated with manual tire pressure checks and adjustments. With automatic
monitoring and inflation capabilities, ATIS ensures that tire pressure remains within the
recommended range, minimizing the need for manual intervention by drivers or maintenance
personnel. This results in improved vehicle reliability, reduced downtime for tire-related issues,
and increased productivity for commercial vehicle fleets.
Furthermore, advancements in ATIS technology are driving innovation and expanding the
capabilities of automatic tire inflation systems. Manufacturers are incorporating features such as
real-time monitoring, wireless connectivity, and predictive analytics to enhance the functionality
and performance of ATIS. Real-time monitoring allows operators to track tire pressure status
remotely, while wireless connectivity enables seamless integration with vehicle telematics
systems for comprehensive fleet management. Predictive analytics algorithms analyze tire
performance data to predict potential issues and optimize maintenance schedules, further
improving vehicle safety and operational efficiency.
In conclusion, the automotive automatic tire inflation system market plays a crucial role in
enhancing vehicle safety, fuel efficiency, and operational efficiency for commercial vehicle
fleets. By automatically maintaining optimal tire pressure, ATIS improves traction, handling, and

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braking performance, reduces fuel consumption and operational costs, and enhances vehicle
uptime and reliability. With ongoing advancements in technology and increasing adoption by
commercial vehicle operators, ATIS is poised to become a standard feature in modern vehicles,
contributing to safer, more efficient, and sustainable transportation solutions.

8.4 Global Automotive Automatic Tire Inflation System Market

The automotive automatic tire inflation system (ATIS) market is experiencing growth across
various regions, including Asia Pacific, North America, Europe & CIS, South America, and the
Middle East & Africa. Automatic tire inflation systems are designed to maintain optimal tire
pressure by automatically adjusting air pressure based on driving conditions. Let's explore the
market overview of each region:
 In the Asia Pacific region, which includes countries like China, India, Japan, and South Korea,
the automotive ATIS market is witnessing steady growth. The region is characterized by a
growing automotive industry, driven by increasing vehicle production and rising consumer
demand for passenger and commercial vehicles. Government regulations mandating the use of
tire pressure monitoring systems (TPMS) to enhance vehicle safety are further fueling the
demand for automatic tire inflation systems in the region.
 North America represents a significant market for automotive ATIS, with the United States
and Canada being major contributors to market growth. The region has a well-established
automotive aftermarket and a high adoption rate of advanced automotive technologies.
Stringent regulations related to vehicle safety and fuel efficiency are driving the adoption of
automatic tire inflation systems in commercial vehicles, leading to market
growth in the region.
 Europe & CIS also constitute a substantial market for automotive ATIS, with countries like
Germany, France, and Russia leading the market. The region is known for its stringent
emission regulations and focus on vehicle safety standards. Increasing awareness among fleet
operators about the benefits of automatic tire inflation systems in improving fuel efficiency,
extending tire life, and enhancing vehicle safety is driving market growth in the region.
 South America is witnessing increasing adoption of automotive ATIS, particularly in
countries like Brazil, Argentina, and Chile. The region's automotive industry is experiencing
growth, driven by economic development and increasing infrastructure investments.

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 Government initiatives aimed at improving road safety and reducing fuel consumption are
driving the demand for automatic tire inflation systems in commercial vehicles in the region.
 The Middle East & Africa region is also showing potential for growth in the automotive ATIS
market, although at a slower pace compared to other regions. The region's automotive industry
is evolving, supported by infrastructure development and increasing foreign investments. The
adoption of automatic tire inflation systems is expected to increase in the commercial vehicle
segment as fleet operators prioritize vehicle efficiency and safety.
Overall, the global automotive automatic tire inflation system market is characterized by growth
across multiple regions, driven by factors such as government regulations, increasing vehicle
safety standards, and the growing awareness of the benefits of automatic tire inflation systems
among fleet operators and vehicle owners. As the automotive industry continues to evolve, the
demand for automatic tire inflation systems is expected to further drive market growth in
the coming years.

8.5 Major companies operating in the Global Automotive Automatic Tire

Inflation System Market are:
 Dana Incorporated
 CLAAS
 Enpro Industries Pvt Ltd
 Michelin
 SAF-HOLLAND
 Meritor
 IDEX Corporation

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 CHAPTER - 9

CONCLUSION
In conclusion, the development of the dynamically-self-inflating tire system represents a
significant advancement in the automotive industry, addressing the critical needs of consumers
while offering substantial economic potential for investors.The proposed system offers a range of
benefits, including reduced tire wear, increased fuel economy, and enhanced overall vehicle
safety. By maintaining optimal tire pressure conditions automatically, it mitigates common
issues associated with underinflated or overinflated tires, thereby improving vehicle performance
and longevity.
Market analysis indicates favorable conditions for introducing the self-inflating tire system, as no
comparable product currently exists for the majority of passenger vehicles. With increasing
consumer awareness of the importance of tire pressure maintenance, there is a growing demand
for innovative solutions that address this need.
Engineering analysis has confirmed the feasibility and functionality of the self-inflating tire
system, demonstrating its capability to provide sufficient airflow to tires while withstanding
static and dynamic loading. Importantly, the system is designed to integrate seamlessly with
existing vehicle components, ensuring compatibility and reliability.
From an economic standpoint, the self-inflating tire system presents lucrative opportunities for
investors. With projected sales of approximately $2.1 million and 58,000 units in the first year
alone and a projected annual market growth of 12% for the first five years, the potential for
profitability is substantial. Moreover, the system is expected to break even on the capital
investment in less than three years, further enhancing its appeal to investors.
Looking ahead, there are opportunities for further development and enhancement of the self-
inflating tire system. Additional features such as pressure adjustment based on vehicle speed and
load, adaptability for recreational use, implementation of interactive displays, and the creation of
a universal design for aftermarket use can further enhance the system's capabilities and market
appeal.
With its combination of consumer benefits, engineering excellence, and economic viability, it
stands poised to make a substantial impact in the market and drive future advancements in

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vehicle technology.

REFERENCES

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1