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11/19/2019
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DESIGNING AND FABRICATION

OF COMPRESSED AIR VEHICLE
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GROUP MEMBERS
DESIGNING FABRICATION

TARIQUE ALI JHATIAL(G.L) 11ME03 UMESH KUMAR(G.L) 11ME143

JAVED AHMED (A.G.L) 11ME07 NAZIR MEMON(A.G.L) 11ME63
ADNAN HANIF 11ME19 NOMEEL MEMON 11ME58
SALMAN NIZAMANI 11ME23 JUNAID AKBAR 11ME59
SHAHBAZ ALI 11ME04 SHEERAZ AHMED 11ME68
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SUPERVISORS

 MR. MUHAMMAD SHARIF JAMALI

 MR. IMTIAZ ALI MEMON

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CONTENTS
Introduction
 History
 Literature Review
 Compressed Air Technology
 Developers & Manufacturer's
 Future Scope
 Parts of Compressed Air Vehicle
 Designing of Compressed Air Vehicle
 Fabrication of Compressed Air Vehicle
 Working of Compressed Air Vehicle
 Advantages of Compressed Air Vehicle
 Disadvantages of Compressed Air Vehicle
 Improvements
 Observations
 References
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INTRODUCTION
These days our world is facing fuel crises and air
pollution.
The primary fuel we are using is gasoline which is
expensive and non-renewable.
So an alternative for gasoline has to be adopted.
Compressed air serves this purpose.
Development of such type of Vehicle which does not
require any of known fuels like diesel, petrol, CNG,
LPG etc but it runs purily on Compressed Air.
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HISTORY
The first recorded compressed-air vehicle in France
was built by the Frenchmen Andraud and Tessie of
Motay in 1838. A car ran on a test track at Chaillot on
the 9th July 1840, and worked well, but the idea was
not pursued further.
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HISTORY
The Mekarski compressed Air Locomotive was a
single-stage engine (air expanded in one piston then
exhausted) and represented an advance in air
engine technology that made air cars feasible: the air
was reheated after leaving the tank and before
entering the engine.

Mekarski Compressed Air Locomotive

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HISTORY
In Hardie Compressed Air Locomotive (1892-1900)
the engine was a one-stage expansion engine using
a more advanced type of reheating than the
Mekarski engine.

Hardie Compressed Air Locomotive

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HISTORY
The Hoadley-Knight system was the first air powered
transit locomotive that used a two-stage engine.

Hoadley-Knight Compressed Air

locomotive
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HISTORY
In 1930, a 1200 horsepower full-size locomotive that
had been developed in Germany. An on-board
compressor was run by a diesel engine, and the air
engine drove the locomotive's wheels. Waste heat
from the diesel engine was transferred to the air
engine where it became fuel again. By conserving heat
in this way, the train's range between fill-ups was
increased 26%.

German Diesel-Pnumatic hybrid locomotive

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HISTORY
Robert C. Burt was a real physicist, he developed a
Burt Air Drive, His compressor was driven by a 4-
cylinder gas engine and the exhaust from the air
engine was re-compressed, so it was both hybrid
and closed-cycle.

Burt Air Drive

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HISTORY
MDI (Motor Development International), France has
proposed a range of vehicles. One of the main
innovations of this company is its implementation of
its "active chamber", which is a compartment which
heats the air (through the use of a fuel) in order to
double the energy output.

MDI Car
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HISTORY

Engine-air is an Australian company which

manufactures small industrial vehicles using an air
engine of its own design.

Di Pietro’s Rotary Engine Di Pietro’s Air Lifter

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LITRTURE REVIEW

COMPRESSED AIR TECHNOLOGY

The compression ,storage and released of air
together are termed as the Compressed Air
Technology
This technology has been utilized in
pneumatic systems.
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LITERATURE REVIEW

This technology under going several years of

research to improve its application.
Compressed air is regarded as the fourth
utility, after electricity, natural gas and water.
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LITERATURE REVIEW

Developers and Manufacturers

Various companies are investing in the research,
development and deployment of compressed air cars.
Here is a brief list of few leading manufacturers who
are putting their concerted efforts towards making
compressed air vehicle a reality for public use.
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Developers and Manufacturers

MDI (Motor Development International), France has

proposed a range of vehicles. One of the main
innovations of this company is its implementation of
its "active chamber", which is a compartment which
heats the air (through the use of a fuel) in order to
double the energy output.
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Developers and Manufacturers

Tata Motors announced in May 2012 that they have
assessed the design passing phase 1, the "proof of
the technical concept" towards full production for the
Indian market. Tata has moved onto phase 2,
"completing detailed development of the compressed
air engine into specific vehicle and stationary
applications".
Air Car Factories South Africa is proposing to
develop and build a compressed air engine.
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Developers and Manufacturers

Engine-air is an Australian company which
manufactures small industrial vehicles using an air
engine of its own design.
In 2010, Honda presented the Honda Air concept car
at the LA Auto Show.
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FUTURE SCOPE
Design and fabrication of a new engine made of light
metal will give the better results.
Usage of compressed air tanks for storage and
supply will give it more scope in automobiles.
Much like electrical vehicles, air powered vehicles
would ultimately be powered through electrical
gird.Transportation of the fuel would not be required
due to the drawing power of electrical gird. This
presents significant cost benefits. Pollution created
during fuel transportation would be eliminated.
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FUTURE SCOPE
New engine designs; as shown in fig shows the
improved variant of the air engine. With these type of
engines; which is more efficient; air powered
automobile could gain the bright scope in the future.

Dipietro Air Engine

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PARTS OF CAV
Frame
A frame is the main structure of the chassis of the
vehicle. All other components fasten to it; a term for this
design is body-on-frame construction

Frame of CAV
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Air Motor
A pneumatic air motor or compressed air engine is a
type of motor which does mechanical work by
expanding compressed air.
It rotates in both direction
(clockwise and anti clock
Wise).

Pneumatic Air Motor

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Air Storage Cylinder

Compressed air energy storage is a way to store
energy generated at one time for use at another time
using compressed air. These are Scuba Tanks made
of Aluminum material. These are used to store air at
2000 psi pressure

Air storage Cylinders

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Steering System
The direction of motion of a motor vehicle is
controlled by a steering system

Steering system
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Shock Absorber
A shock absorber is a mechanical device designed to
smooth out,or damp shock impulse, and convert kinetic
energy to another form of energy (usually thermal
energy, which can be easily dissipated).

Shock Absorber
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Chain Drive
Chain drive is a way of transmitting mechanical
power from one place to another.

Chain Drive & Sproket

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Brake System
A brake is a mechanical device which inhibits motion,
slowing or stopping a moving object or preventing its
motion.

Brake Drum
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DESIGNING OF CAV

Designing of Compressed Air Vehicle has been done

by using applications of Parametric Technology
Corporation (PTC) Pro/ENGINEER Wildfire 5.0.
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DESIGN OF FRAME

Designed Frame Of CAV

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DESIGN OF RIMS

Designed Rim
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DESIGN OF WHEELS

Designed Wheel
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DESIGN OF STEERING SYSTEM

Designed Steering System

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DESIGN OF STORAGE CYLINDER

Designed Storage Cylinder

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DESIGN OF AIR MOTOR

Designed Air Motor

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DESIGN OF FITTINGS

Designed Fitting Pipes

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DESIGN OF DRIVING SEAT

Designed Driving Seat

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ASSEMBLY OF ALL COMPONENTS

Final assembled View of CAV

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FABRICATION OF COMPRESSED AIR

VEHICLE
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FABRICATION OF CAV
 Fabrication is a process of the construction of machines
and structures from various raw materials.
 Fabrication is done by cutting, bending, welding and
assembling process of the components.
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Fabrication Of Frame
Frame Material selection:
The material used for the fabrication of frame is the
‘’Wrought iron square tubes’’
Why wrought iron ?
It is inexpensive.
It is soft and ductile.
Having high elasticity and tensile strength.
It is easy to weld and easily sustain the load.

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Steps to fabricate the Frame

Cut the square tubes into desire dimension.
Weld the square tube pieces as per design.
Grind the welded joints to remove the excess
material and get the smoother surface.
Inspect the all welded joints and dimension.

Fabricated Frame
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Installation of the Wheels

Installation of the front Wheels

Apply the thin layer of the grease on the skewer rod.
Hold the wheel in proper alignment and insert the
skewer rod into the hub.
 Tighten the nut on skewer rod.
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Installation of the rear wheel and sprocket

Larger sprocket is bolted with the rear wheel of the
vehicle.
placed the chain on the sprocket.
Now insert the skewer rod in the hub and sprocket
and tighten the nut on the skewer rod.
 Finally aligned the wheels.

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Installation of Air Motor

First made the base for the air motor by welding the
sheet on the frame.
Drill the holes in the sheet for the motor assembly.
Then motor was placed on that plate-form in such a
way that inlet for air in motor was exactly front to the
tanks and motors silencer was at the back parallel to
rear wheel.
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Now tighten the nut and bolts for assemble the

moter with the base of the welded sheet.

Assembled Pneumatic Motor

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Installation of Steering System

 Steering system is installed at the center of the vehicle and it
is supported with the help of two rods.

 Baisc rack and pinon steering is used in CAV.

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It consist of the following components:

Tie Rod
Two tie rod assemblies are used to fasten the center
link to steering knuckles.

Tie Rod
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Idler Arm
 The idler arm bolts to the vehicle's frame that supports the
end of the center link on the passenger’s side of the vehicle.
Center link
 It connects the pitman arm and idler arm.

Idler Arm Center link

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Pitman Arm
It is the component which translates the radial
motion of the steering shaft into the linear motion to
turn the wheels.

Pitman Arm
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Rack & Pinion

In rack & pinion, the pinion gear is attached to the
steering shaft.
The rack-and-pinion gear set does two things:
It converts the rotational motion of the steering wheel
into the linear motion needed to turn the wheels.
It provides a gear reduction, making it easier to turn
the wheels.
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Installation of Shock Absorber and

Driver seat
Bolt the front legs of seat on the frame of vehicle and
rear legs are kept free.
Shock absorber consist of the helical spring.
A rod is insert in helical spring and one end of rod is
welded to the driver seat and other is free.
Purpose of rod to keep the spring in straight form.
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One end of shock absorber is tightened against the

vehicle body and the other one is fitted with the
driver seat

Assembled Driveng Seat

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Installation of Chain & Sprocket

Small sprocket is welded on the shaft of the air
motor.

Chain & sprocket

After that the rear sprocket (larger) is bolted with the

rear wheel of the vehicle.
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Installation of Chain & Sprocket

Mount the chain on the both front and rear

sprockets.
Adjust the chain tightness Lubricate properly.
so that power can be transferred from motor to
rear wheel.
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Installation of Break to Rear Wheel

Drum brake system is used in the vehicle .
Brake paddle is bolted I front of driver seat.
A long metallic cable is used to connect the paddle
and the brake.

Installed Break Of Rear Wheel

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It is the simple brake system just like in motor bike.

Brake Padel
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WORKING OF CAV

A pneumatic motor, known as a rotary vane motor,

uses air to produce rotational motion to a shaft.
The rotating element is a slotted rotor which is
mounted on a drive shaft.
Compressed air from cylinders to the air motor
through the pipes.
For check the output pressure of cylinder and input
pressure of motor use the pressure gauges.
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WORKING OF CAV

Regulating valve beside the diving seat to control the

air flow ( speed of the vehicle)
Air is pumped through the motor input which pushes
on the vanes creating the rotational motion of the
central shaft
Rotation speeds can vary between 100 and 24,00
rpm depending on several factors which include the
amount of air pressure at the motor inlet and the
diameter of the housing.
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WORKING OF CAV

With the shaft of motor and chain and

sprocket assembly is made through which the
power is transmitted to the rear wheel of the
Vehicle.
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ADVANTAGES OF CAV
Much like electrical vehicles, air powered vehicles
would ultimately be powered through the electrical
grid, which makes it easier to focus on reducing
pollution from one source, as opposed to the millions
of vehicles on the road.
Transportation of the fuel would not be required due
to drawing power off the electrical grid. This presents
significant cost benefits. Pollution created during fuel
transportation would be eliminated.
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ADVANTAGES OF CAV

Compressed air technology reduces the cost of

vehicle production by about 20%, because there is
no need to build a cooling system, fuel tank, Ignition
Systems.
Air, on its own, is non-flammable.
The mechanical design of the engine is simple.
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ADVANTAGES OF CAV

The tank may be able to be refilled more often and in

less time than batteries can be recharged, with re-
fuelling rates comparable to liquid fuels.
Compressed-air tanks can be disposed of or
recycled with less pollution than batteries.
Lighter vehicles would mean less abuse on roads.
Resulting in longer lasting roads
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DISADVANTAGES OF CAV
Less power output
Probability of air leakage
Tanks get very hot when filled rapidly
Biggest disadvantage is the energy needed to
compress the air is greater than the energy stored
At the supply station, compressing the air heats it,
and if then directly transferred in a heated state to
the vehicle storage tanks will then cool and reduce
the pressure. If cooled before transfer, the energy in
this heat will be lost unless sophisticated low grade
heat utilization is employed
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IMPROVMENTS

With use of Air Motor instead of internal

combustion engine (70 cc) we have increased
its running speed from 15 km/hr to 40 km/hr.
As well as weight of vehicle is reduced which
results in increased efficiency of vehicle
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OBERVATIONS
 Motor RPM = 2400
 Motor HP = 0.5
 Weight of Vehicle = 70 kg
 Tank Air Storage Capacity = 3 kg
 Pressure Inside Tanks = 138 Bar = 2000 Psi
 Pressure at Inlet of Motor = 69 Bar = 1000 Psi
 Weight of Driver = 60 kg
 Total Load on Vehicle = weight of vehicle + Driver weight
= 70 + 60
= 130 kg
 Running speed of Vehicle = 40 km/h
 Distance covered per kg of Air = 300 m
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REFERENCES
 Study and Fabrication of Compressed Air Engine. JP Yadav and Bharat
Raj Singh
 Fabrication and Testing of Compressed Air Car Dr. Anirudh Addala,
Srinivasu Gangada
 Mechanical Engineering and Design, Tata McGraw Hill, Ed. 3rd
 Book Refer. William H Crouse on Automotive Mechanics
 Wiki Foundation Wikipedia Website.
 How Stuff Works Website.
 Engineering Hobbyist Website.
 Engine Air Website
 Sharma P.C. & Aggarwal D.K., Machine Design, S.K. Kataria & Sons, Ed.
11th Reprint.
 Mahadevan & Reddy, Design Data Handbook, CBS Publishers, Ed. 3rd
 Mechanical Engineering and Design, Tata McGraw Hill, Ed. 3rd
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