AUTOMATIC DIFFERENTIAL UNIT LOCKING

SYSTEM FOR FOUR WHEELER

PROJECT REPORT 2008-2009

Submitted by
(team name)

COLLEGE LOGO

Guided by:

Submitted in partial fulfillment of the requirement for the

Award of Diploma in -----------------------------------------

By the State Board of Technical Education Government of

Tamilnadu, Chennai.

Department:

College name:

Place:
 COLLEGE NAME

COIMBATORE

DEPARTMENT OF MECHANICAL ENGINEERING

PROJECT REPORT-2008-2009

This Report is certified to be the Bonafide work done by

Selvan/Selvi ---------------- Reg.No.------------ of VI
Semester class of this college.

Guide Head of the Department

Submitted for the Practical Examinations of the board of

Examinations,State Board of Technical Education,Chennai,
TamilNadu.On --------------(date) held at the ------------
(college name),Coimbatore

Internal Examiner External Examiner

DEDICATED TO OUR BELOVED
PARENTS
ACKNOWLEDGEMENT
 ACKNOWLEDGEMENT

At this pleasing movement of having successfully completed our

project, we wish to convey our sincere thanks and gratitude to the
management of our college and our beloved
chairman------------------------.who provided all the facilities to us.

We would like to express our sincere thanks to our principal

------------------for forwarding us to do our project and offering adequate
duration in completing our project.

We are also grateful to the Head of Department prof…………., for

her/him constructive suggestions &encouragement during our project.

With deep sense of gratitude, we extend our earnest &sincere thanks

to our guide --------------------, Department of Mechanical for her/him kind
guidance and encouragement during this project we also express our indebt
thanks to our TEACHING staff of MECHANICAL ENGINEERING
DEPARTMENT, ---------- (college Name).
AUTOMATIC DIFFERENTIAL UNIT
LOCKING SYSTEM FOR FOUR
WHEELER
CONTENTS

CONTENTS
CHAPTER NO TITLE

SYNOPSIS
LIST OF FIGURES
NOMENCLATURE
1 Introduction
2 Literature review
3 Description of equipments
3.1 Pneumatic control components
3.2 Valves
3.3 Hoses
3.4 Pressure Gauge
3.5 Control unit
3.6 Differential unit
4 Design and drawing
4.1 Pneumatic components and Specification
4.2 Design Calculation
5 Working principle
6 Merits and demerits
7 Applications
8 List of materials
9 Cost Estimation
10 Conclusion
Bibliography

Photography
LIST OF FIGURES
 LIST OF FIGURES

Figure
Number Title

1 Piston Rod
2 Piston
3 Double acting pneumatic cylinder
4 Hose Collar
5 Solenoid valve (cut off valve)
6 Overall Diagram
 NOMENCLATURE

NOMENCLATURE

 A =Area of cylinder(m2 )
 D=Diameter of Piston (m)

 F =Force exerted on the piston (N)

 H=Height (m)

 L=Length(m)

 P=Pressure (N/m2)

 V=Volume (m3)
SYNOPSIS
 SYNOPSIS

The proposed Mechanism is to lock the differential. By locking

the differential is disengaged from the axle. Thus the power is directly

transmitted to the axle and hence to the wheels. This will

considerable reduce the power loss in some occasions when

unwanted loss is happening due to the transmission if power from the

shaft to the differential and then to the axle and hence to the wheels.

So in mechanism the unwanted power loss in the due course of

transmission through the differential is reduced.

 CHAPTER-1
INTRODUCTION
 CHAPTER – 1

INTRODUCTION

Vehicles, derived from the Latin word, vehiculum, are non-living

means of transport. Most often they are manufactured (e.g. bicycles,

cars, motorcycles, trains, ships, boats, and aircraft), although some

other means of transport which are not made by humans also may be

called vehicles; examples include icebergs and floating tree trunks.

Vehicles may be propelled or pulled by animals, for instance, a

chariot, a stagecoach, a mule-drawn barge, or an ox-cart. However,

animals on their own, though used as a means of transport, are not

called vehicles, but rather beasts of burden or draft animals. This

distinction includes humans carrying another human, for example a

child or a disabled person.

A rickshaw is a vehicle that may carry a human and be powered by a

human, but it is the mechanical form or cart that is powered by the

human that is labeled as the vehicle. For some human-powered

vehicles the human providing the power is labeled as a driver.

Vehicles that do not travel on land often are called craft, such as

watercraft, sail craft, aircraft, hovercraft, and spacecraft

Land vehicles are classified broadly by what is used to apply steering

and drive forces against the ground: wheeled, tracked, railed, or skied

NEED FOR AUTOMATION

Automation can be achieved through computers, hydraulics,

pneumatics, robotics, etc., of these sources, pneumatics form an

attractive medium for low cost automation.

The main advantages of all pneumatic systems are economy

and simplicity. Automation plays an important role in mass

production.

Nowadays almost all the manufacturing process is being

atomized in order to deliver the products at a faster rate.The

manufacturing operation is being atomized for the following reasons.

 To achieve mass production

 To reduce man power

 To increase the efficiency of the plant

 To reduce the work load

 To reduce the production cost

 To reduce the production time

 To reduce the material handling

 To reduce the fatigue of workers

 To achieve good product quality

 Less maintenance
 CHAPTER-2

LITERATURE SURVEY
 CHAPTER-II

LITERATURE SURVEY

PNEUMATICS

The word ‘pneuma’comes from greek and means breather

wind. The word pneumatics is the study of air movement and its

phenomena is derived from the word pneuma.today pneumatics is

mainly understood to means the application of air as a working

medium in industry especially the driving and controlling of machines

and equipment.

Pneumatics has for some considerable time between used for

carrying out the simplest mechanical tasks in more recent times has

Played a more important role in the development of pneumatic

technology for automation.

Pneumatic systems operate on a supply of compressed air

which must be made available in sufficient quantity and at a pressure

to suit the capacity of the system. When the pneumatic system is

being adopted for the first time, however it wills indeed the necessary

to deal with the question of compressed air supply.

 The key part of any facility for supply of compressed air is by

means using reciprocating compressor. A compressor is a machine

that takes in air, gas at a certain pressure and delivered the air at a

high pressure.

Compressor capacity is the actual quantity of air compressed

and delivered and the volume expressed is that of that of the air at

intake conditions namely at atmosphere pressure and normal

ambient temperature.

The compressibility of the air was first investigated by Robot

Boyle in 1962 and that found that the product of pressure and

volumes of particular quantity of gas.

The usual written as

PV =C (or) PiVi =P2V2

In this equation the pressure is the absolute pressured which

for free is about 14.7Psi and is of courage capable of maintaining a

column of mercury, nearly 30 inches high in an ordinary barometer.

Any gas can be used in pneumatic system but air is the mostly used

system now a days.

SELECTION OF PNEUMATICS

Mechanization is broadly defined as the replacement of manual

effort by mechanical power. Pneumatic is an attractive medium for

low Cost mechanization particularly for sequential (or) repetitive

operations. Many factories and plants already have a compressed air

system, which is capable of providing the power (or) energy

requirements and control system (although equally pneumatic control

systems may be economic and can be advantageously applied to

other forms of power).

The main advantages of an all pneumatic system are usually

Economic and simplicity the latter reducing maintenance to a low

level. It can have out standing advantages in terms of safety.

PNEUMATIC POWER

Pneumatic systems use pressurized gases to transmit and

control power. Pneumatic systems typically use air as the fluid

medium because air is safe, low cost and readily available.

THE ADVANTAGES OF PNEUMATICS

1. Air used in pneumatic systems can be directly exhausted back

In to the surrounding environment and hence the need of special

reservoirs and no-leak system designs are eliminated.

2. Pneumatic systems are simple and economical

3. Control of pneumatic systems is easier

THE DISADVANTAGES OF PNEUMATICS

1.Pneumatic systems exhibit spongy characteristics due to

compressibility of air.

2. Pneumatic pressures are quite low due to compressor design

limitations(less that 250 psi).

PRODUCTION OF COMPRESSED AIR

Pneumatic systems operate on a supply of compressed air,

which must be made available. In sufficient quantity and at a pressure

to suit the capacity of the system. When pneumatic system is being

adopted for the first time, however it wills indeed the necessary to

deal with the question of compressed air supply.

The key part of any facility for supply of compressed air is by means

using reciprocating compressor. A compressor is a machine that

takes in air, gas at a certain pressure and delivered the air at a high

pressure. Compressor capacity is the actual quantity of air

compressed and delivered and the volume expressed is that of the air

At intake conditions namely at atmosphere pressure and normal

ambient temperature.

Clean condition of the suction air is one of the factors, which

decides the life of a compressor. Warm and moist suction air will

result increased precipitation of condense from the compressed air.

Compressor may be classified in two general types.

1. Positive displacement compressor

2. Turbo compressor

Positive displacement compressors are most frequently employed for

Compressed air plant and have proved highly successful and supply

air for pneumatic control application.

The types of positive compressor

1. Reciprocating type compressor

2. Rotary type compressor

 Turbo compressors are employed where large of air required at

low discharge pressures. They cannot attain pressure necessary for

pneumatic control application unless built in multistage designs and

are seldom encountered in pneumatic service.

RECIPROCATING COMPRESSORS

Built for either stationary (or) portable service the reciprocating

compressor is by far the most common type. Reciprocating

compressors lap be had is sizes from the smallest capacities to

deliver more than 500m3/min.In single stage compressor, the air

pressure may be of 6 bar machines discharge of pressure is up to

15bars.Discharge pressure in the range of 250bars can be obtained

with high pressure reciprocating compressors that of three & four

stages. Single stage and 1200 stage models are particularly suitable

For applications, with preference going to the two stage design as

soon as the discharge pressure exceeds 6 bars, because it in

capable of matching the performance of single stage machine at

lower costs per driving powers in the range.

DIFFERENTIAL UNIT

A sun gear 6 is concentrically, rotatably disposed inside an

internal gear 4. Plural planet gears 8, carried by a planetary carrier

10, are disposed between and in meshing engagement with the

internal gear 4 and the sun gear 6. The planetary carrier 10 is

connected to a shaft extending from an engine while the internal gear

4 and the sun gear 6 are connected to output shafts. The internal

gear 4 is molded by a plastic working, followed by a thermal

treatment including soft-nitriding, a nitriding and a carburizing

hardening step. The inner surface of the internal gear 4 is formed with

internal gear teeth 4b, except for an axial portion 4d, while a spline

groove 4a is formed on the outer surface of the internal gear 4 at a

location corresponding to the portion 4d where no internal teeth 4b

are formed for engagement with a spline 2a on a housing 2. The

internal gear 4 is reduced in size while improving the mechanical

strength thereof.
 CHAPTER-3

DESCRIPTION OF EQUIPMENT
 CHAPTER-III

DESCRIPTION OF EQUIPMENTS

3.1 PNEUMATIC CONTROL COMPONENT

3.1.1 PNEUMATIC CYLINDER

An air cylinder is an operative device in which the state input

energy of compressed air i.e.penuamtic power is converted into

mechanical Output power, by reducing the pressure of the air to that

of the atmosphere.

3.1.1a) single acting cylinder:

Single acting cylinder is only capable of performing an

operating medium in only one direction. Single acting cylinders

equipped with one inlet for the operating air pressure, can be

production in several fundamentally different designs. Single

cylinders Develop power in one direction only.

Therefore no heavy control equipment should be attached to

them, which requires to be moved on the piston return stroke single

action cylinder requires only about half the air volume consumed by a

double acting for one operating cycle.

3.1.1 B) Double acting Cylinders

A double acting cylinder is employed in control systems with the

full pneumatic cushioning and it is essential when the cylinder itself is

required to retard heavy messes. This can only be done at the end

positions of the piston stroke. In all intermediate position a separate

externally mounted cushioning derive most be provided with the

damping feature.

The normal escape of air is out off by a cushioning piston

before the end of the stroke is required. As a result the sit in the

cushioning chamber is again compressed since it cannot escape but

slowly according to the setting made on reverses. The air freely

enters the cylinder and the piston strokes in the other direction at full

Force and velocity.

3.2 VALVES

SOLENOID VALVE

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

system. Commonly known as DCV; this valve is used to control the

direction of air flow in the pneumatic system. The directional valve

does this by changing the position of its internal movable parts.

This valve was selected for speedy operation and to reduce the

manual effort and also for the modification of the machine into

automatic machine by means of using a solenoid valve.

A solenoid is an electrical device that converts electrical energy

into straight line motion and force. These are also used to operate a

mechanical operation which in turn operates the valve mechanism.

Solenoid is one is which the plunger is pulled when the solenoid is

energized.

The name of the parts of the solenoid should be learned so that

they can be recognized when called upon to make repairs,to do

service work or to install them.

PARTS OF A SOLENOID VALVE

1. Coil

The solenoid coil is made of copper wire. The layers of wire are

separated by insulating layer. The entire solenoid coil is covered with

a varnish that is not affected by solvents, moisture, cutting oil or often

fluids. Coils are rated in various voltages such as 115 volts

AC,230volts AC,460volts Ac,575 Volts AC.6Volts DC,12Volts DC,

24 Volts DC,115 Volts DC &230Volts DC.they are designed for such

Frequencies as 50Hz to 60Hz.

2. Frame

The solenoid frame serves several purposes. Since it is made

of laminated sheets, it is magnetized when the current passes

through the coil.the magnetized coils attract the metal plunger to

move. The frame has provisions for attaching the mounting. They are

usually bolted or welded to the frame. The frame has provisions for

receivers, the plunger. The wear strips are mounted to the solenoid

frame, and are made of materials such as metal or impregnated less

Fiber cloth.

3. Solenoid plunger

The solenoid plunger is the mover mechanism of the solenoid. The

plunger is made of steel laminations which are riveted together under

high pressure, so that there will be no movement of the lamination

with respect to one another. At the top of the plunger a pin hole is

placed for making a connection to some device. The solenoid plunger

is moved by a magnetic force in one direction and is usually returned

by spring action.
Solenoid operated valves are usually provided with cover either the

solenoid or the entire valve. This protects the solenoid from dirt and

other foreign matter, and protects the actuator. In many applications it

is necessary to use explosion proof solenoids.

WORKING OF SOLENOID VALVE

The solenoid valve has 5 openings. These ensure easy

exhausting of 5/4Valve.the spool of the 5/4 valve slide inside the main

bore according to spool position: the ports get connected and

disconnected.

The working principle is as follows.

Position-1

When the spool is actuated towards outer direction port ‘P’ gets

Connected to ‘B’ and ‘S’ remains closed while ‘A’gets connected to

‘R’.

Position-2

When the spool is pushed in the inner direction port ‘P’ and ‘A’

Gets connected to each other and ‘B’ to ‘S’ while port ‘R’remains

closed.
SOLINOID VALVE (OR) CUT OFF VALVE

The control valve is used to control the flow direction is called

cut off valve or solenoid valve. This solenoid cutoff valve is controlled

by the electronic control unit.

In our project separate solenoid valve is used for flow direction

of vice cylinder. It is used to flow the air from compressor to the single

acting cylinder.

3.2.2 FLOW CONTROL VALVE

In any fluid power circuit, flow control valve is used to control

the speed of actuator. The flow control can be achieved by varying

the area of flow through which the air in passing.

When area is increased,more quantity of air will be sent to

actuator as a result its speed will increase. If the quantity of air

entering into the actuator is reduced, the speed of the actuator is

reduced.

3.2.3 PRESSURE CONTROL VALVE

The main function of the pressure control valve is to limit (or)

Control the pressure required in a pneumatic circuit.

Depending upon the method of controlling they are classified as

1. Pressure relief valve

2. Pressure reducing valve

3.3. HOSES

Hoses used in this pneumatic system are made up of

polyurethane. These hose can with stand at a maximum pressure

level of 10 x105N/m2 .

CONNECTORS

In our system there are two type of connectors used. One is the

Hose connector and the other is the reducer. Hose connectors

normally comprise an adopt hose nipple and cap nut. These types of

connectors are made up of brass (or) aluminum (or) hardened

pneumatic steel.

3.4 PRESSURE GAUGE

Pressure gauges are usually fitted with the regulators. So the

air Pressure adjusted in the regulator is indicated in the pressure

Gauge, is the line pressure of the air taken to the cylinder.

3.5 CONTROL UNIT

In pneumatic multipurpose device is an air-operated device

used for many small operations. It is a portable one. Compressed air

is the source of energy for this device. The compressed air is allowed

through the nozzle in such a way to rotate to fan> the rotation is

utilized for machining.

The nozzle are welded the fan can be rotated in either

directions by operating by one-way works. The rpm and torque of the

shaft depends upon the pressure of the air admitted so by varying the

pressured the RPM and torque can be varied. Thick tubes

interconnect the parts. The clamps are used at the connecting parts

to prevent leakage. In thread parts seals are used to prevent leakage.

Here the compressed air form the compressor firstly enters the

Control unit. In the control unit the pressure of the air is controlled unit

the pressure of the air is controlled and sent to the barrel to rotate the

fan in any one direction. The gate valve controls the pressure volume

of air.
 Then the pressure is read by a pressure gauge. Then the air is

admitted to the barrel, a shaft is placed and if carries the fan. The

shaft is supported in either and by bearing. The bearings are placed

in the Couplings, which covers the end of barrel.

3.6 DIFFERENTIAL UNIT

A differential is a device, usually but not necessarily employing

gears, capable of transmitting torque and rotation through three

shafts, almost always used in one of two ways. In one way, it

receives one input and provides two outputs; this is found in most

automobiles. In the other way, it combines two inputs to create an

output that is the sum, difference, or average, of the inputs.

In an automobile and other wheeled vehicles, the differential allows

each of the driving wheels to rotate at different speeds, while

supplying equal torque to each of them. In automotive applications,

the differential and its housing are sometimes collectively called a

"pumpkin" (because the housing resembles a pumpkin).

A vehicle's wheels rotate at different speeds, especially when turning

corners. The differential is designed to drive a pair of wheels with

equal force, while allowing them to rotate at different speeds. In

vehicles without a differential, such as karts, both driving wheels are

forced to rotate at the same speed, usually on a common axle driven

by a simple chain-drive mechanism. When cornering, the inner wheel

travels a shorter distance than the outer wheel, resulting in the inner

wheel spinning and/or the outer wheel dragging. This results in

difficult and unpredictable handling, damage to tires and roads, and

strain on (or possible failure of) the entire drive train.

The following description of a differential applies to a "traditional"

rear- or front-wheel-drive car or truck:

Power is supplied from the engine, via the transmission , to a drive

shaft (British term: propeller shaft, more commonly abbreviated to

"prop-shaft"), which runs to the differential. A spiral bevel pinion gear

at the end of the propeller shaft is encased within the differential

itself, and it meshes with the large spiral bevel ring gear (British term:

crown wheel). (The ring and pinion may mesh in hypoid orientation,

not shown.) The ring gear is attached to a carrier, which holds what is

sometimes called a spider, a cluster of four bevel gears in a

rectangle, so each bevel gear meshes with two neighbors and rotates

counter to the third, that it faces and does not mesh with. Two of

these spider gears are aligned on the same axis as the ring gear and

drive the half shafts connected to the vehicle's driven wheels. These

are called the side gears. The other two spider gears are aligned on a

perpendicular axis which changes orientation with the ring gear's

rotation. These two gears are just called pinion gears, not to be

confused with the main pinion gear. In the two figures shown above,

only one pinion gear (green) is illustrated. (Other spider designs

employ different numbers of pinion gears depending on durability

requirements.) As the carrier rotates, the changing axis orientation of

the pinion gears imparts the motion of the ring gear to the motion of

the side gears by pushing on them rather than turning against them

(that is, the same teeth stay in contact), but because the spider gears

are not restricted from turning against each other, within that motion

the side gears can counter-rotate relative to the ring gear and to each

other under the same force (in which case the same teeth do not stay

in contact).

Thus, for example, if the car is making a turn to the right, the main

ring gear may make 10 full rotations. During that time, the left wheel
will make more rotations because it has further to travel, and the right

wheel will make fewer rotations as it has less distance to travel. The

side gears will rotate in opposite directions relative to the ring gear

by, say, 2 full turns each (4 full turns relative to each other), resulting

in the left wheel making 12 rotations, and the right wheel making 8

rotations.

The rotation of the ring gear is always the average of the rotations of

the side gears. This is why if the wheels are lifted off the ground with

the engine off, and the drive shaft is held (preventing the ring gear

from turning inside the differential) manually rotating one wheel

causes the other to rotate in the opposite direction by the same

amount.

When the vehicle is traveling in a straight line, there will be no

differential movement of the planetary system of gears other than the

minute movements necessary to compensate for slight differences in

wheel diameter, undulations in the road (which make for a longer or

shorter wheel path), etc.

 CHAPTER-4

DESIGN AND DRAWING

 CHAPTER-IV

DESIGN OF EQUIPMENT AND DRAWING

4.1 PNEUMATIC COMPONENTS AND ITS SPECIFICATION

The automatic differential unit locking system is consists of the

following components to full fill the requirements of complete

operation of the machine.

1. Double acting pneumatic cylinder

2. Solenoid vale

3. Flow control valve

4. Connectors

5. Hoses

6. Differential unit

7. Control unit

1. Double acting pneumatic cylinder:

Technical Data

Stroke length: cylinder stroke length 100mm =0.1m

Piston rod : 10mm =10 X10-3m

Quantity : 1
Seals : Nitride (Buna-N) Eastover

End cones : Cast iron

Piston : EN-8

Media : Air

Temperature: 0-80°C

Pressure Range: 8N/m2

2.Solenoid Flow control valve:

Technical data

Port Size : 0.635x10-2m

Maximum pressure: 0-10 x10 5 N/m2

Range

Quantity: 1

Media : Air

3. Connectors

Technical data

Max working pressure : 10 x105 N/m2

Temperature : 0-100°C

Fluid media :Air

Material :Brass

4. Hoses

Technical data

Max pressure : 10 x105 N/m2

Outer diameter : 6mm =6 x 10-3 m

Inner diameter : 3.5mm =3.5 x10-3m

Pneumatic unit

Type of cylinder : Double acting cylinder

Type of valve : flow control valve &solenoid valve

Max air pressure : 8 x105 N/m2

4.2 DESIGN CALCULATION

Max pressure applied in the cylinder (p) : 8N/m2

Area of cylinder (A) : (3.14/4*(D 2)

: 80.38cm2

: 80.38 X 10-4m2
Force exerted in the piston (F) : Pressures applied X area-

-of cylinder.
DRAWING
DRAWING FOR AUTOMATIC DIFFERENTIAL UNIT
LOCKING SYSTEM
 CHAPTER -5

WORKING PRINCIPLE
 CHAPTER-V

WORKING PRINCIPLE

There are some drawbacks in the existing mechanism and we

overcome it in the proposed project. The first is while climbing in

steep hills the differential is not really needed as the speed of the

vehicle is low. And also there are some transmission loses in the

differential. So at this time the unit is locked and the loss is overcome.

Then when a heavy truck is struck in a pit or mud it is very difficult to

recover the truck as the differential unit cuts the power which is to be

transmitted to the wheel struck. So in this project the unit is

disengaged and power is directly given to the axle by pneumatic

means and so the recovery is made easier. This is even made use in

the vehicle to be driven in the dense forests and even in dessert.

A differential is a device which is used in vehicles oven a few

decades and when a vehicle is negotiating a turn, the outside wheel

travels a greater distance and turns faster than the inside wheel. The

differential is the device transmitting the power to each wheel, allows

one wheel to turn faster than the other. It splits the engine torque two

ways, allowing each output to spin at a different speed. The

differential is found on all modern cars and trucks, and also in many

all-wheel-drive (full-time four-wheel-drive) vehicles.

These all-wheel-drive vehicles need a differential between each

set of drive wheels, and they need one between the front and the

back wheels as well, because the front wheels travel a different

distance through a turn than the rear wheels. Part-time four-wheel-

drive systems don’t have a differential between the front and rear

wheels; instead, they are locked together so that the front and rear

wheels have to turn at the same average speed. This is why these

vehicles are hard to turn on concrete when the four-wheel-drive

system is engaged.

The main purpose of this project is to lock the differential or to

disengage the differential at the time when it is needed to be. So to

lock the differential we need to connect the two shafts on the either

side so that the differential has no effect on the axle. Now to connect
the two shafts we use two circular plates on the either sides of the

differential.

Both are in such a way that they get mated as soon as possible

even in their rotation. So when the pneumatic valve is actuated then

one of the plates is pushed to the other so that the plates get mated

and hence the shafts are connected. So thus the differential is

disengaged. To engage the differential again a spring is used to push

the plates apart. Thus this is the working principle of the project
 CHAPTER -6

MERITS AND DEMERITS

 CHAPTER-VI

MERITS AND DEMERITS

MERITS

 Less Manual force is required to locking the differential unit

 This Pneumatic system is also working with the help of air tank

 Time Consumption is less

 More Efficient system and simple in construction

DEMIRTS

 Noised operation

 Cylinder stroke length is constant

 Need a separate compressor

 CHAPTER-7

APPLICATIONS
 CHAPTER-VII

APPLICATION

 It is applicable in heavy vehicle and four wheelers etc..,

 CHAPTER-8

LIST OF MATERIALS
 CHAPTER-VIII

LIST OF MATERIALS

FACTORS DETERMINING THE CHOICE OF MATERIALS

The various factors which determine the choice of material are

discussed below.
1. Properties:

The material selected must posses the necessary properties for

the proposed application. The various requirements to be satisfied

Can be weight, surface finish, rigidity, ability to withstand

environmental attack from chemicals, service life, reliability etc.

The following four types of principle properties of materials

decisively affect their selection

a. Physical

b. Mechanical

c. From manufacturing point of view

d. Chemical

The various physical properties concerned are melting point, thermal

Conductivity, specific heat, coefficient of thermal expansion, specific

gravity, electrical conductivity, magnetic purposes etc.

The various Mechanical properties Concerned are strength in tensile,

Compressive shear, bending, torsional and buckling load, fatigue

resistance, impact resistance, eleastic limit, endurance limit, and

modulus of elasticity, hardness, wear resistance and sliding

properties.

The various properties concerned from the manufacturing point

of view are,

 Cast ability

 Weld ability

 Bribability

 Forge ability

 Merchantability

 Surface properties

 Shrinkage

 Deep drawing etc.

2. Manufacturing case:

Sometimes the demand for lowest possible manufacturing cost or

surface qualities obtainable by the application of suitable coating

substances may demand the use of special materials.

3. Quality Required:

This generally affects the manufacturing process and ultimately

the material. For example, it would never be desirable to go casting of

a less number of components which can be fabricated much more

economically by welding or hand forging the steel.

4. Availability of Material:

Some materials may be scarce or in short supply. It then

becomes obligatory for the designer to use some other material which

though may not be a perfect substitute for the material designed. the

delivery of materials and the delivery date of product should also be

kept in mind.

5. Space consideration:

Sometimes high strength materials have to be selected because the

forces involved are high and space limitations are there.

6. Cost:

As in any other problem, in selection of material the cost of

material plays an important part and should not be ignored.

Some times factors like scrap utilization, appearance, and non-

maintenance of the designed part are involved in the selection of

proper materials.

S.No DESCIRPTION QTY Material

1 Double acting 1 aluminum

pneumatic cylinder
2 Solenoid Valve 1 aluminum

3 Flow control valve 1 aluminum

4 Control unit 1 Electronic

5 PU tubes 5meter polyurethane

 CHAPTER-9

COST ESTIMATION
 CHAPTER-IX

COST ESTIMATION

1.MATERIAL COST.

2. LABOUR COST:

Lathe, drilling, welding, drinding, power hacksaw, gas cutting cost

3. OVERGHEAD CHARGES:

The overhead charges are arrived by”manufacturing cost”

Manufaturing Cost =Material Cost +Labour Cost

Overhead Charges =20%of the manufacturing cost

4. TOTAL COST:

Total cost = Material Cost +Labour Cost +Overhead Charges

Total cost for this project =

CHAPTER-10

CONCLUSION
 CHAPTER-X

CONCLUSION

The project carried out by us made an impressing task in the

field of automobile department. It is very useful to the drivers while

drive in the hill station roads etc..,

This project will reduce the cost involved in the concern. Project

has been designed to perform the entire requirement task at the

shortest time available.

BIBLIOGRAPHY
 BIBLIOGRAPHY

1. Design data book -P.S.G.Tech.

2. Pneumatic handbook -R.H.warrning

3. Machine tool design handbook –Central machine tool

Institute, Bangalore.

4. Strength of Materials -R.S.Kurmi

5. Manufacturing Technology -M.Haslehurst.

6. Design of machine elements- R.s.Kurumi

PHOTOGRAPHY