INDEX

1. ACKNOWLEDGEMENT

2. INTRODUCTION

3. AIMS OF PROJECT

4. A SELECTION OF PROJECT

5. PROJECT PLLANNING

6. MARKET SURVEY

7. MARKET FEASIBILITY

8. DEFINATION OF PROJECT

9. INTRODUCTION OF AIR CASTER

10. ELEMENTS OF AIR CASTER

11. HOW AIR CASTER WORKS

12. FLORS FOR AIR CASTER

13. DIFFERENT FORMS OF AIR CASTER

14. COSTING

15. COST ESTIMATING

16. CONCLUSION

2
 ACKNOWLEDGEMENT

I am highly in debated to our guide SHRI M.P.PATEL (Head of mech.

Dept.) and SHRI M.N.PATEL (Lect. Of Mech. Dept.) For the invaluable guidance
isspiration and kind help for to progress and to complete my MINOR PROJECT
WORK ON AIR CASTER.

I am also expressing my thanks to SHRI M.N.PATEL (Lect. Of Mech. Dept)

For the guidance and valuable suggestion for complication of my project work.

Moreover I take on opportunity to express my since gratitude to SHRI

D.P.PATEL and other instructress of work shop who directly and indirectly helped us
to carry out of my project work.

Thanking you.

3
 INTRODUCTION
In throughout diploma, we have studied in detail about
fundamental of engineering processes, machine tools, machine design,
strength of material, heat transfer, metrology, management, costing etc. in this
semester we have been given an opportunity to exhibit our learning abilities
through project work.

During the project work all aspect of engineering fields are

convered. In diploma mechanical engineering the purpose of introducing the
subject is to devlop our…

1: Attitude of inquiry

2: Ability of exploring ideas

3: Ability of Selection

4: Market surveying

5: Ability of process / product planning

6: Ability of resolving problems

7: Team Work and etc.

In sort project is summer of D.M.E. we feels our selves lucky to have project A
good team work.

4
 AIMS OF PROJECT WORK

The course aims listed above can be achieved by designing

suitable learning experiences in classroom laboratory following aims could
be achieved:

1. To provide planning and decision making skills.

2. To gate the knowledge of each student in various subjects which he has

studies before.

3. To provide with experience and practice of teaching problems. They are

likely to meet in industry.

4. To integrate and reinforce skills required the student separate subject.

5. To provide interdisciplinary studies.

6. To develop higher level skills.

7. To present student with an excition and demanding challenge.

8. To develop ability to work in a team.

5
 PROJECT SELECTION

IDENTIFYING YOUR PROJECT

While you have been steadily improving your entrepreneurial and
managerial qualities, understanding the commandments and familiarizing your
self within rules, regulation polices, constrains, incentives, assistance and
facilier being offered by the government and financial institutions your mind
must be silently scanning the different projects choose the one most suited to
you this is critical decision which should not be arrived at abruptly or without
deliveration, identifying of your project should be systematic and preceded by
market survey, research information gathering and discussions. A step by step
approach is given below.

After scanring a large number of product make short list of 5 to 10

products which suit your expertise aptitude and temperament.

Study the project cost and market cost for the above items.

Factors which should weigh in the final selection should be.

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 PROJECT PLANNING
Planning is a mental processes recovering the use of intellectual
facilities, imagination etc. It means deciding in advance what is to be done,
how and where it is to be done, who will do it & how results are to be
evaluated.

In other words planning is determination of course of action to

achieve the desired result, planning is sequence of action through which it is
expected to reach the objective. This all planning involves events. It is the
process of thinking before during planning is to focuswhich means both to
cross future and make provisions far it.

 PLANNING ADVANTAGES

1. Planning given direction.

2. Planning focus attention on activities.
3. Planning is most important in cost estimating.
4. Planning is help in economical matter of economic.

7
 MARKET SURVEY
You need to check for your self the market prospects of the products
Selected by you before you lunch a venture. You should not rely merely
upon institution or hear say to assess the market prospects. A comprehension
market study is must be specific advantages of such a study are:

(a) I t enables to evaluate the valuability of an enterprise by arcing a Year

by year estimate of sales.

(b) It makes it possible for you to estimate scale and utilization of installed
capacity with reference to the proposed enterprice.

(c) You can judge whether the proposed capacity is on thehigher or lower
side.

(d) It provides a preliminary input for marketing strategy programme

Formulation for the enterprise.

8
 MARKETING FEASIBILITY
Market survey is essential before planning the actual production. During
market considering other available similar Products, their future, demand,
price, and quality.

Market survey has to know about location of market scope and Sales
availability of raw material equipments, man power other Manufacturing
facilities. After considering above all facts mass Production should be
planned.

On basis concepts pf product the market survey and group Discussion

we find that our project “ AIR CASTER ” Will be very use full from SSI (Small
Scale Industries) too large Engineering production unit where air caster based
production is Being performed.

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 DEFINATION OF PROJECT

“ A project should enables a student exercise. Some of the knowledge

& or Skills developed during programme ( Upto the time that the particulars
projects to initiated) to a nev situation of problem for which there are a number
of engineering solutions. The project will in the time allotted the maintenance
of a log book & the preparation of a report. The project should not have a
single solution & in the process of arriving at a particular allusion the student
must be required to make a number of decision after studying the differentative
& base his decision of information he has accumulated from experiments,
analysis, survey etc. The report should obtain the reasons for all decision
taken.

The subject “ Project work” is offered to the student of final year in

which they have to make any m/c of attitude which is based on the principle of
mechanical Engg.

The student have to use their knowledge which is obtain by them in

previous semester. Good term work result in good project.

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 AIR CASTER

 INTRODUCTION:-
There is a need of moving one object from one place to another in any
factory or work shop. This can be accomplished manually or by power operated
devices. Some machines are so heavy that they can’t be lifted or moved manually.
Power operated devices like cranes are used for this task, but these devices are very
costly and very costly and also they consume large amount of power. There is a
change of accident with these devices. Also, skilful operator is required to operate it.

In view of above difficulties, a need arises for some kind of devise which is
easy to operate, simple in design, economical, yet very efficient This needs can be
fulfilled by a new innovative concept. And that is “ AIR CASTER- The load mover”

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 WHAT IS AN AIR CASTER ?
Air caster technology is provide easier and free transport of
various types of loads, regardless of weight or size. Air casters use a
continuous, regulated flow of air to create an air film between an
inflated bearing element and the floor surface . the air casters are
mounted to a rigid platform to provide load carrying. and the load to lift
and float, virtually friction- free omni- directional movement is achieved.

 PRINCIPLE OF OPERATION :-

 The air caster works on an “ AIR CUSHION MOBILITY

SYSTEM”

 An “air cushion mobility system” is any system that employs a

cushion of air to separate the load from the ground (or other bearing
surface). The common HOVERCRAFT is one well known application
of an “ air cushion mobility system.

 It employs air to loft the load. The lateral movement can

sometimes be provided by the came air or by any other external
force.

 Air casters use most advanced air seals. These seals employ
a flexible wear foot mounted below a completely protected inflatable
hanger. Since this inflated hanger does not come in contact with the
surface over which the seal is operated all wear is taken by the wear
foot. This inexpensive wear foot can be replaced whenever
necessary without replacing the remainder of the seal assembly.

 Air is forced into the hangers which inflate. After the hangers
are inflated fully, air is forces under the war foot. The air lifts the
wear foot just enough to create an air gap. Once this is created a
very small (approximately 1 kg for every 1 ton of load) force is
needed to move the load.

 Air caster thus provides omni-directional virtually frictionless

mobility for the load. This allows effortless movement and accurate
positioning of heavy loads. Unlike trucks and trains they require no
turning radius, i.e. they can rotate around their own axes. Also the
pressure exerted in the case of air casters is much lower.

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 If for some reason the air supply is cut off the load come to a
quite, smooth, safe rest almost immediately. The air still in the
hanger acts like a shock absorber.

 If the floor surface is covered with metal shavings, chips,

cutting oil and solvents,the load floating air casters simply push and
blow the debris aside leaving a clean path. No damage can possibly
occur to the inflated diaphragm protected as it is by the wear foot.
The seals can also be inflated independently of the “ air cushion”.

 This makes it possible to float the air casters at reduced

heights under a skid-mounted load and then inflate the seals fully to
lift the skids clear of the floor transferring the weight to the air caster.

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 ELEMETS OF AN CASTER SYSTEM:-

1. CIRCULAR RUBBER TORUS:-

An air caster is made of reinforced rubber. The circular
rubber torus is vulcanized to an anodized aluminium back plate.

2. LANDING PAD:-
When the air caster is deflated, the load rests on the
lending pad in the center of the module. On larger capacity models
the air caster also includes pads in the corners for added support.

3. BACK PLAT:-
The aluminium/steel back plate is bolted to a rigid load
platform. The load module top plate is an aluminium/ steel extrusion,
with a very high strength to weight ratio.

4. COMPRESSOR:-
Compressor is needed for the continuous supply of
pressurized air. The supply of compressed air enters through a port in
the module. The rating of compressor depends upon the load to be
moved by the Air caster.

14
 MAKING OF AIR CASTER:-

o The raw material such as steel rings , steel plates, strip of steel,
etc.required for making an air caster are purchased from a junkyard. For
our model we have rubber tube of truck in place of circular rubber torus.

o First of all, the steel plate is cut to the required size on the
hacksaw machine and debarred by hand grinding.

o The steel rings are concentrically on steel plate and welded on

two spots to ensure proper alignment during welding. We had marked 8
points on bigger and 4 point on smaller ring for drilling the hole of size 6
mm. and we also made a hole on the plate for compressed air
connection.

o Then we had welded the elbow to the steel plate on the hole and
tightened the valve at an elbow.

o We departed rings from plate by hammering and then fit the

rubber tube on the plate by smaller ring. As the thickness of the ring is
very small we have put additional rubber packing between ring and
rubber tube.

15
o The next step is to put the packing of clothes to make a tours
shape and make the hole in accordance with the holes made on steel
ring.

o The inner edge of steel ring is chamfered for protection of rubber

tube.

o A solution is lapped between rubber tube and ring to prevent

leakage and then make assembly.

o A wooden load pad is attached with the help of nuts and bolts.

HOW AIR CASTER WORKS:-

Modules are fitted to a special load platform or individually

positioned directly under the load. In order to achieve stability, at least
three, but most often four, modules are placed under the load. These are
connected through a pneumatic control unit, to a compressed air supply.
Modules should be positioned as far apart as possible in order to
optimize the weight distribution and load stability. Once the modules
have been positioned, the valves can be opened individually. AIR IS
SUPPLEID TO THE TORUS GREATING a thin air film on which the load
floats with a minimum of friction. A seal is formed between the floor
surface and the torus. The pressure in the air bearings can be increased
slowly until lift the load and it starts to float. The load can then be moved
and be positioned exactly as required.

16
SR. NO. NAME OF PART DIMENSIONS QUANTITY
(mm*mm)

1. Wooden plate 1200*1200*18 1

2. M.S. steel plate 400*400*5 4
3. Bigger ring 4
4. Smaller ring 4
5. Rubber tube - -
6. Nuts & bolt
7. Elbows & T & - 4
clamp
8. Nipple & tape - -
9. Nozzle 4
10. Hose pipe - -
11. Valve - 4
SIZE SPECIFICATIONS AND COSTING:-

 FOR SMALL AIR CASTER:-

17
 Performance of Air Caster:-

When the pressure of compressed over the air is

slightly increased over the pressure exerted by the external load, the air
film is created and load can be moved easily. We know that.

Pressure = Load /area

The weight of smaller air caster is about 5 kg. whereas the weight of
bigger air caster is about 10 kg.

The mean diameter of torus = 15 cm

 In no load position the pressure of air can be calculated as,

(For Smaller)

P= FORCE/ AREA

= 5/{(p/4) X 152}

= 0.05 kg/ cm2

(For Bigger)

P = FORCE/ AREA

= 10/ {(p/4) X152}

 On load position the pressure of air can be calculated as,

(For smaller)

P = FORCE/ AREA

= 60/ {(p/4) X 152}

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 = 0.34 kg/cm2

(For Bigger)

P= FORCE/ AREA

= 160 / {(p/4) X 152 }

= 0.91 kg/ cm2

Load Capacities:-

By smaller air caster around 100 kg load can be moved

easily similarly by bigger air caster load about 225 kg can be displaced.

Commercially available air casters systems can lift loads

as right up to 200000 kg and beyond.

A standard single 12- inch air caster is capable of lifting

around 1000 pounds (1/2 ton) on its own. When used in normal system
of four linked modules this capacity is raised to 4000 pounds (2 tons).

A heavy duty 48- inch air caster can easily lift 30 tones
on its own, so when coupled with a system of four it will increase to a
lifting of over 120 tons. By using sets of different air bearing sizes and air
pressures we are able to supply systems than can easily lift over 200
tons and more.

19
 FLOORS FOR AIR CASTER
TRANSPORT:-

In order to reap the full benefits of air caster transport one

must pay attention to the properties of the floor surface. A correctly
chosen floor will pay dividends in terms of low operating cost and easy
handling.

An unsuitable surface could lead not only to high

traction forces due to friction but also to high air consumption and
excessive wear of the air caster. Inclination or undulation (“sloping”) of
the floor will also increase thee required traction power which might call
for the use of powered drive units in addition to the air caster.

Following are some of the main requirements for the floor surface.

 The floor surface should be air tight so as to enable formatting of a

load- bearing air film between the floor and the load carrier.

 The floor surface be smooth as to smooth as to minimize the air

consumption and the friction.

 The floor surface must be even (with out inclinations) so that load
does not glide away because of law friction.

FLOORS FOR FREQUENT USE:-

The floor should be smooth, non- porous and level. A machine

toweled, epoxy treated concrete floor is ideal- however the job should be
carefully done without marks, pits, cracks, flaking or messy painting.
Most modern floors in new plants meet these demands, if not it is
normally possible to achieve a good result through the use of suitable
fillers and epoxy paint. The illustrations (below) display the allowed
maximum undulations and inclinations.

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 SMOOTHNESS

Section through an air caster shows the pressure chamber and

the thin (.005”) air film on which the load rides. One can easily appreciate
why, producting grains must be avoided. Cracks or holes in the floor will
make the pressure disappear.

 UNDULATIONS

Due to their elasticity, the air caster adjusts to minor unevenness.

The level differences should,however, not be more than 2% of the
diameter of the air cushion.

 INCLINATON

21
 The floor inclination should be kept within certain limits for safe
handling of the goods. You cannot escape gravity – it is heavy going
uphill and easy downhill.

 NON-AIRTIGHT FLOORS

On a non-airtight surface, the air cushions may loose so

much air that the pressure is not adequate for lifting the load, i.e. to from
the load- bearing air film. A normal concrete floor without surface –
treating is porous and let’s the air pass through. Also airtight floor can
contain joints, holes and cracks, which can easily bee filled or covered
with tape.

 JOINTS

The expansion joints shall be filled with an elastic

composition. The best material is rubber -like urethane composition, the
shore hardness being approx. 80 in orders to fill the joint properly, a joint
width of approx. 3/8” is recommended. The joint composition can
preferably be slightly above the floor surface.

The figure below gives a idea of recommended joints of

floors of air caster.

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 OLD FLOOR

It is often necessary to improve to improve the floor

surface with filling composition. Grinding is sometimes needed for
binding the composition to the surface.

 FLOOR SMOOTHNESS

The floor smoothness is a matter of great importance when

judging a floors suitability for air bearing transport. Although there are a
number of measuring devices available on the market there is a lack of
universal norms. In the last resort, one is left to make a visual evaluation.

Normally one cannot operate on the following surface:

 Tarmac
 Dirt roads
 Metal Grilles
 Checker plate

If we need to drive temporarily on such surfaces, surface be covered

with sheet metal or similar.

 FLOOR COVERING FOR OCCASIONAL TRANSPORT

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 Occasional or infrequent transport of heavy equipment on
surfaces not suited for air bearing transport can steel be carried out if we
covers the floor with, for example, sheet metal, vinyl floor sheeting or
measure board(smooth side up). Any cracks, pot holes, drains, cable
ducts, etc… must be covered and filled with e.g. wet sand or plaster .

 STEPS

Air casters have a limited ability to negotiate steps and sharp

ramps. For example: an air caster with diameter of 36” cannot travel
either up or down from the edge of piece of sheet metal 0.12” thick
(the equivalent of 11 gauge sheet metal). The sharp edge cuts
through the air film and the membrane rubs against the edge. Steps
that can be handled depends in practice on the size of the air bearing
and the pressure used. Large, low pressure bearings with left can
negotiate higher steps than small Air Bearings using high pressure.
The height of a step should, generally speaking, not exceed the
demands on flatness given earlier. One should always try to even out
steps in order to achieve a smooth.

 FLOR LOADING

It is obvious that the floor must be strong and rigid enough to

carry the load. Compared to wheeled transport there is, however, a
great advantage in using air casters. Air casters transport has a much
better load distribution, which leads to lower demand on the floor
strength compared with wheeled transport. The floor load is very small
in air cushion transports due to the big air cushion surface, elasticity
and minor dead weight when compared with equipment on wheels.
Easily damaged floors such as parquet, linoleum, clinker and surfaces
with floor heating are not damaged during Air Film Transports.

24
 DIFFERENT FORMS OF AIR CASTER:-

 The Air Pallet Transporter:-

Previously all transformer controls were manual and

balancing valves, or through a separate remote control system. The
manual and remote control systems are still available, but as an
alternative, these new air pallets gives the operator full control of the
transporter through the push handle assembly at the rear of the pallet.

Air pallets are equipped with a push handle assembly at the

rear which allows the operator tighter control of the operational settings.
The push handle assembly houses twin handlebar grips trigger switch to
25
start and stop operation, main air inlet from shop air supply, and air
balancing valves to ensure that all bearings are receiving the correct
amount of air in relation to the weight of the load and the condition of the
floor on which the air pallet is operating.

Air pallets have a low profile of around 2+ inches, and are

easily moved on a thin film of air that is created when the air bearings
are powered by regular compressed shop air. Omni – directional control
is a breeze for just one person (for loads of up to 3 tons) via the
handlebars on the push assembly. Air is directed to the air bearings via a
trigger switch set just below one of the handles. What could be easier for
pallet handling?

Air pallets are able to move loads from just 500 pounds to
10 tons and beyond, are available in many width sizes- starting around 3
ft. – and are easily customized to suit the customers specifications –
ranging from the foot print size of the pallet, to a pick and lift air pallet
that is able to lift its load vertically before floating it off to its destination.
The pick and lift system is especially useful if the customer is using low
profile air pallets to hold the load, instead of setting the load directly on
the air pallet.

ROUND STEEL MODULES:-

26
 ELEMANTS OF AIR CASTER

1. Wooden Plate

2. M.S. steel plate

3. Bigger ring

4. Smaller ring

5. Rubber tube

6. Nuts & tube

7. Elbows & T & clamp

8. Nipple & tape

9. Nozzle

10. Hose pipe

11. Valve

27
 COSTING

Costing is the technique and process of ascertaining costs. It is the

classifying recording and appropriate allocation of expenditure for
determination of the cost of the production or service.

 ELEMENTS OF COST :
1. MATERIAL COST

 DIRECT MATERIAL COST

The cost of material which becomes a part of production
or product it self after various processes is called direct material cost.
E.g. oil, metal.

 INDIRECT MATERIAL COST

Material which is essentially required to operate the
equipment and material cost for such material is called indirect material
cost. E.g. oil, coolant, grease etc.

2. LABOUR COST

 DIRECT LABOUR COST

The labour which is actually perform the manufacturing
process on different machines is called direct labour cost.

28
  INDIRECT MATERIAL COST
The labour which is not directly released with
manufacturing of product but this kind of man power helps to perform
direct labour on product is called indirect labour cost such is called
indirect labour cost.

3. EXPENSES

 DIRECT EXPENSES
The expenses which can be directly charged on the cost
of particular product are called direct expenses.

 INDIRECT EXPENSES
The expenses which can not be directly on the cost a
particular product is called indirect expenses.

MATERIAL COST

SR. NO. NAME OF PART DIMENSIONS QUANTITY COST IN

(mm*mm) RS.
1. Wooden plate 1200*1200*18 1 1200/-
2. M.S. plate 400*400*5 4 1800/-
3. Bigger ring - 4 1200/-
4. Smaller ring - 4 500/-
5. Rubber tube - - 500/-
6. Nuts & bolt - - 300/-
7. Elbows & T & clamp - 4 100/-
8. Nipple & tap - - 50/-
9. Nozzle - 4 100/-
10. Hose pipe - - 200/-
11. Valve - 4 200/-
TOTAL 6250/-

LABOUR COST

29
SR.NO. NAME OF THE COMPONENT RATES
1. M.S. steel plate fitting 200/-
2. Ring fitting 250/-
TOTAL 450/-

OVERHEAD COST
9 % OF PRIME COST 603/-

COSTING CALCULATION

1. Prime cost = Direct Material + Direct Labour

= 6250+450
= 6700/- Rs.

2. Overhead Cost = 9% of Prime cost

= 603/-Rs.

3. Total Cost = Prime cost + Overhead Cost

= 6700+603
= 7303/-Rs.

30
 CONCLUSION

Only the conclusion is the way for present the

experience while Making the project. After completing the
project “ AIR CASTER ”. We are happy and glad with well
and good Satisfaction. We have credited lost of ideas and
knowledge in technical field To our resource of the same
while making this project. We have been able to learn lot
and understand the various aspects of manufacturing.

31