DESIGN AND FABRICATION OF PNEUMATIC ENGINE

A PROJECT REPORT

Submitted By:

R.RAGUL KANNA (821116114305)

S.ARUNPANDIYAN (821116114503)

E.BAZEER (821116114502)

K.VINOTH (821116114083)

in partial fulfillment for the award of the degree

of

BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING

KINGS COLLEGE OF ENGINEERING

ANNA UNIVERSITY, CHENNAI

APRIL 2019

i
 BONAFIDE CERTIFICAT

Certified that this project “DESIGN AND FABRICATION OF

PNENUMATIC ENGINE ” is the bonafide work of “R.RAGUL KANNA
(821116114305), S.ARUNPANDIYAN(821116114503), E.BAZEER
(821116114502), K.VINOTH (821116114083)” who carried out the project
under my supervision.

SIGNATURE SIGNATURE

Dr.T.PUSHPARAJ,M.E.,Ph.D., MR.J.PRINCE JEROME

CHRISTOPHER.,M.E.,(Ph.d).,

Head of the Department,Professor, Assistant Professor,

Department of Mechanical Engg, Department of Mechanical Engg,

Kings College of Engineering, Kings College of Engineering,

Pudukkottai – 613 303. Pudukkottai – 613 303.

Submitted for the ANNA UNIVERSITY examination held on

INTERNAL EXAMINER EXTERNAL EXAMINER

ii
 ACKNOWLEDGEMENTS

We would like to convey our sincere thanks to our respected Secretary

Dr.R.Rajendran, M.A., M.Phil., Ph.D., for giving us the opportunity to display
our professional skills through this project.

We would like to thank our Principal Dr.J.Arputha Vijaya Selvi, M.E.,

Ph.D., and our respected Head of the Department of Mechanical Engineering
Dr.T.Pushparaj, M.E., Ph.D., for motivating us to reveal our innovative skills.

We express our deep sense of gratitude to our project guide Mr.J.

Prince Jerome christopher., M.E.,(Ph.d)., Assistant professor, Department of
Mechanical Engineering and project coordinator Mr.J.Rajaparthiban, M.E.,
(Ph.D)., Assistant professor, Department of Mechanical Engineering for their
valuable guidance and motivation, which helped us to complete this project.

We thank all our teaching and non-teaching staff members of the

Mechanical engineering department for their passionate support, for helping us to
identify our mistakes and also for the appreciation they gave us in achieving our
goal. We heartily thank our library staff and management for their extensive
support by providing the information and resources that helped us to complete
the project successfully. Also, we would like to record our deepest gratitude to
our parents for their constant encouragement and support which motivated us to
complete our project on time.

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 ABSTRACT

This paper work deals with the Compressed-air engine as a pneumatic actuator that
converts one form of energy into another. The Air Driven Engine is an eco-friendly
engine which operates with compressed air. This Engine uses the expansion of
compressed air to drive the pistons of the engine. An Air Driven Engine is a
pneumatic actuator that creates useful work by expanding compressed air. There is
no mixing of fuel with air as there is no combustion. An Air Driven Engine makes
use of Compressed Air Technology for its operation The Compressed Air
Technology is quite simple. If we compress normal air into a cylinder the air would
hold some energy within it. This energy can be utilized for useful purposes. When
this compressed air expands, the energy is released to do work. So this energy in
compressed air can also be utilized to displace a piston. Compressed air propulsion
may also be incorporated in hybrid systems, e.g., battery electric propulsion and
fuel tanks to recharge the batteries. This kind of system is called hybrid-pneumatic
electric propulsion. Additionally, regenerative braking can also be used in
conjunction with this system.

iv
 TABLE OF CONTENTS

CHAPTER TITLE PAGE NO

NO
ABSTRACT iv
TABLE OF CONTENTS ⅴ
LIST OF TABLES ⅵ
LIST OF FIGURES ⅶ
1 INTRODUCTION 1
1.1 Compressed air engine basics 2
1.2 History 3-4
1.3 Applications 4-5
1.4 Advantages 5-6
1.5 Disadvantages 6-7
2 LITERATURE REVIEW 8-11
3 PROBLEM IDENTIFICATION 12
4 OBECTIVES 13
5 WORKING PRINCIPLE 14-16
6 LINE DIAGRAM & DESIGN CALCULATION 17-22
7 DESCRIPTION OF COMPONENTS 23-31
8 FABRICATION EQUIPMENT 33-34
9 ASSEMBLY OF FABRICATION MODEL 36
10 CONCLUSION 38
COST ESTIMATION 39
REFERENCES 40-41

v
 LIST OF TABLES

TABLE NO TITLE PAGE NO

6.1 SPECIFICATION 21

10.1 MATERIAL COST 39

10.2 MACHINING COST 39

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 LIST OF FIGURES

FIGURE NO TITLE PAGE NO

1.2.1 PARSEY’S COMPRESSED AIR ENGINE 3

5.1 CYLINDER CRANK CONNECTION 15

5.2 WORKING FLOW CHART 16

6.1 LINE DIAGRAM 18

6.2-6.5 CAD MODELLINGS 19-20

7.1 PNEUMATIC CYLINDER 24

7.2 AIR COMPRESSOR 26

7.3 LEVER CONTROL VALVE 27

7.5 CRANK SHAFT 28

7.6 HOSE 28

7.7 ROLLER BALL BEARING 29

7.8 PRESSURE REGULATOR 31

8.1 ARC WELDING MACHINE 33

8.2 CUTTING MACHINE 34

9.1-9.2 ASSEMBLY OF FABRICATION MODEL 36

vii
CHAPTER 1 : INTRODUCTION
1.1 Compressed air engine basics

1.2 History

1.3 Applications

1.4 Advantages

1.5 Disadvantages

1
1.1 COMPRESSED AIR ENGINE BASICS:

A Compressed-air engine is a pneumatic actuator that creates

useful work by expanding compressed air. A compressed-air vehicle is powered by
an air engine, using compressed air, which is stored in a tank. Instead of mixing
fuel with air and burning it in the engine to drive pistons with hot expanding gases,
compressed air vehicles (CAV) use the expansion of compressed air to drive their
pistons. They have existed in many forms over the past two centuries, ranging in
size from hand held turbines up to several hundred horsepower. For example, the
first mechanically-powered submarine, the 1863 Plongeur, used a compressed air
engine.

The laws of physics dictate that uncontained gases will fill any
given space. The easiest way to see this in action is to inflate a balloon. The elastic
skin of the balloon holds the air tightly inside, but the moment you use a pin to
create a hole in the balloon's surface, the air expands outward with so much energy
that the balloon explodes. Compressing a gas into a small space is a way to store
energy. When the gas expands again, that energy is released to do work. That's the
basic principle behind what makes an air car go.Some types rely on pistons and
cylinders, others use turbines. Many compressed air engines improve their
performance by heating the incoming air, or the engine itself. Some took this a
stage further and burned fuel in the cylinder or turbine, forming a type of internal
combustion engine.

One manufacturer claims to have designed an engine that is 90 percent efficient.

Compressed air propulsion may also be incorporated in hybrid systems, e.g.,
battery electric propulsion and fuel tanks to recharge the batteries. This kind of
system is called hybrid-pneumatic electric propulsion. Additionally, regenerative
braking can also be used in conjunction with this system.
2
1.2 HISTORY:
a) The first compressed-air vehicle was devised by Bompas, a patent for a
locomotive being taken out in England in 1828. There were two storage
tanks between the frames, with conventional cylinders and cranks. It is not
clear if it was actuallybuilt. (Knight, 1880)
b) 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.

Fig. 1.2.1 parsey’s compressed air engine

c) In 1848 Barin von Rathlen constructed a vehicle which was reported to

have beendriven from Putney to Wandsworth (London) at an average
speed of 10 to 12 mph
d) At the end of 1855, a constructor called Julienne ran some sort of vehicle
at Saint-Denis in France, driven by air at 25 atmospheres (350 psi), for it to
be used in coal mines

3
 e) Compressed air locomotives were use for haulage in 1874 while the
Simplon tunnel was being dug. An advantage was that the cold exhaust air
aided the ventilation of the tunnel
f) Louis Mékarski built a standard gauge self-contained tramcar which was
tested in February 1876 on the Courbevoie-Etoile Line of the Paris
Tramways Nord (TN), where it much impressed the current president and
minister of transport Maréchal de MacMahon. The tramcar was also shown
at the exhibition of 1878 as it seemed to be an ideal transport method,
quiet, smooth, without smoke, fire or the possibility of boiler explosion
g) The compressed-air locos were soon withdrawn due to a number of
accidents, possibly caused by icing in the pipes of the brakes, which were
also worked by compressed air.
h) In Louis Mékarski built a standard gauge self-contained tramcar which was
tested in February 1876 on the Courbevoie-Etoile Line of the Paris
Tramways Nord (TN), where it much impressed the current president and
minister of transport Maréchal de MacMahon. The tramcar was also shown
at the exhibition of 1878 as it seemed to be an ideal transport method,
quiet, smooth, without smoke, fire or the possibility of boiler explosion

1.3 APPLICATIONS:

The compressed air engine can be used in many vehicles. Some of its
applications
to be used as engine for vehicles are:
a) Mopeds Jem Stansfield, an English inventor has been able to convert a
regular scooter to a compressed air moped. This has been done by
equipping the scooter with a compressed air engine and air tank.

4
 b) Buses
MDI makes MultiCATs vehicle that can be used as buses or trucks.
RATP has also already expressed an interest in the compressed-air
pollution-free bus
c) Locomotives
Compressed air locomotives have been historically used as mining
locomotives and in various areas
d) Trams
Various compressed-air-powered trams were trialed, starting in 1876
and has been successfully implemented in some cases.
e) Watercraft and aircraft
Currently, no water or air vehicles exist that make use of the air
engine. Historically compressed air engines propelled certain
torpedoes
1.4 ADVANTAGES:
The advantages are well publicised since the developers need to make their
machines attractive to investors. Compressed-air vehicles are comparable in
many ways to electric vehicles, but use compressed air to store the energy
instead of batteries. Their potential advantages over other vehicles include:

a) 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.

5
 b) 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
c) 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 or silencers.
d) Air, on its own, is non-flammable.
e) High torque for minimum volume
f) The mechanical design of the engine is simple and robust.
g) Low manufacture and maintenance costs as well as easy maintenance.
h) Compressed-air tanks can be disposed of or recycled with less
pollution than batteries.
i) Compressed-air vehicles are unconstrained by the degradation
problems associated with current battery systems.
j) 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.
k) Lighter vehicles would mean less abuse on roads. Resulting in longer
lasting roads.
l) The price of fuelling air-powered vehicles will be significantly
cheaper than current fuels.
1.5 DISADVANTAGES:

Like the modern car and most household appliances, the principal disadvantage is
the indirect use of energy. Energy is used to compress air, which - in turn -
provides the energy to run the motor. Any conversion of energy between forms
results in loss. For conventional combustion motor cars, the energy is lost when oil

6
is converted to usable fuel - including drilling, refinement, labour, storage,
eventually transportation to the end-user. For compressed-air cars, energy is lost
when electrical energy is converted to compressed air.

a) When air expands, as it would in the engine, it cools dramatically (Charles

law) and must be heated to ambient temperature using a heat exchanger
similar to the Intercooler used for internal combustion engines. The heating
is necessary in order to obtain a significant fraction of the theoretical energy
output. The heat exchanger can be problematic. While it performs a similar
task to the Intercooler, the temperature difference between the incoming air
and the working gas is smaller. In heating the stored air, the device gets very
cold and may ice up in cool, moist climates.
b) Refuelling the compressed air container using a home or low-end
conventional air compressor may take as long as 4 hours though the
specialized equipment at service stations may fill the tanks in only 3 minutes
c) Tanks get very hot when filled rapidly. SCUBA tanks are sometimes
immersed in water to cool them down when they are being filled. That
would not be possible with tanks in a car and thus it would either take a long
time to fill the tanks, or they would have to take less than a full charge, since
heat drives up the pressure
d) Early tests have demonstrated the limited storage capacity of the tanks; the
only published test of a vehicle running on compressed air alone was limited
to a range of 7.22 km.
e) ) A 2005 study demonstrated that cars running on lithium-ion batteries

outperform both compressed air and fuel cell vehicles more than three-fold
at same speeds. MDI has recently claimed that an air car will be able travel
140km in urban driving, and have a range of 80 km with a top speed of 110

7
 CHAPTER 2

LITERATURE REVIEW

8
LITERATURE REVIEW:

Vishwajeet Singh[1] The review of literature gives a brief introduction

to the evolution of CAE; it presents the problem of leakage and inefficiency that
are faced while designing the components of CAE and how they can be overcome.
Further it also covers the advantages of using CAE in reducing the energy crises
and lowering the global warming. However, the concept of running the car using
CAE still need some focus in developing infrastructure to power the car . This
paper presents the concept of my CAE design, presents the concept of modifying a
conventional 4-stroke internal combustion engine into a 2-stroke engine to run
using compressed air technology, presents the basis for my CAE testing, and
discussesits advantages and give an overview on CAE future development

Prof. B. S. Patel et al[2] Who tried to develop such a compressed air

engine by modifying an 4-stroke, single cylinder SI engine by replacing the spark
plug with the help of pulsed pressure valve, and using compressed air as the
working fluid which id pollution free or tend to zero pollution. The working of this
engine is very well explained theoretically and the cost analysis is made which
shows that the compressed air engine is cheaper than Spark ignition engine i.e. SI
engine on the frame of reference of conventional SI engine

Dr. Bharat Raj Singh & Dr. Onkar Singh[3] conducted together in which
they both used a wanned type novel air turbine as a prime mover for a motor bike.
In this experiment they tried to gain an output of 6.50 Horsepower i.e.4.84705
Kilowatt to 7.20 Horsepower i.e.5.36904 Kilowatt for the starting torque
requirements of 500 to 750 rpm at 4 to 6 bars air pressure to running speeds of
2000 to 3000 rpm using 2 to 3 bars air pressure. The test was conducted in HBTI

9
Kanpur After conducting this research they have concluded that
overallperformance of air turbine for working Pressure ranging from 2.7-6 bar is
found varying from 72%-97%. This technology can be used in the area under the
future automotive industry.

SwadhinPatnaik[4]This paper work deals with the Compressed-air engine

as a pneumatic actuator that converts one form of energy into another. The Air
Driven Engine is an eco-friendly engine which operates with compressed air. This
Engine uses the expansion of compressed air to drive the pistons of the engine. An
Air Driven Engine is a pneumatic actuator that creates useful work by expanding
compressed air. There is no mixing of fuel with air as there is no combustion. An
Air Driven Engine makes use of Compressed Air Technology for its operation The
Compressed Air Technology is quite simple. If we compress normal air into a
cylinder the air would hold some energy within it. This energy can be utilized for
useful purposes. When this compressed air expands, the energy is released to do
work. So this energy in compressed air can also be utilized to displace a piston.
Compressed air propulsion may also be incorporated in hybrid systems, e.g.,
battery electric propulsion and fuel tanks to recharge the batteries. This kind
of system is called hybrid-pneumatic electric propulsion. Additionally,
regenerative braking can also be used in conjunction with this system. .

Pramod Kumar .J [5] The principle behind the working of the Air
powered Engine is the ability of air to store energy on compression and then
release the same on expansion. On compression, the work done by the pump gets
stored as pressure energy. This compressed air is then stored in cylinders/tanks for
later use. When this air is allowed to expand, the pressure energy of air gets
converted to kinetic energy and causes propulsion. The same principle is used for
engines. A throttling mechanism is attached to the cylinder opening valve from the

10
throttle. When the required rotation is provided to the throttle, the valve opens to a
particular degree controlling the amount of air delivered out. This air is delivered
to the engine. When the compressed air enters the engine through the inlet valve it
strikes the piston, which moves (reciprocate) causing first half rotation of the crank
shaft, this striked air gets expanded which then moves to the out through the outlet
during the 2nd half rotation of the crank shaft . The air is stored either in cylinder
or compressor. The sole purpose of storing air at such high pressure is to ensure
that there is enough volume of air present in the vehicle to allow it to run for a long
period of time before having to refill the cylinder. The working of the engine is as
shown in the

Prof. R.V. Chaudhary[6] We were able to successfully complete the

design and modification of the Petrol Vehicle in to the Compressed air vehicle.
The Air Vehicle provides an effective use and applied to the transportation light
vehicles. It’s speed, range and the power are limited now, so further research could
provide more effective results. This project can be directly utilized in the market to
modify IC Engine bikes in to the Air bikes in effective cost. Since a number of
operations can be performed in a single and simple unit. It is efficient and
economical. We can say that the cost of the modification is very less and the
effective results can be achieved. As we know that in IC engines higher pressures
and temperatures are maintained as compared to air driven engine so that in IC
engines heavy metal alloys are used but for air driven engine light alloys can be
used. The weight of the engine can be reduced by using aluminium and more light
metals. Also the new modified engine and chassis, cast from light alloys can be
lighter which will design for the air engine. The use of heater and reuse of exhaust
air improves the efficiency of the vehicle. This project is a successful one because
we have stared the 4 Stroke petrol vehicle is running only on compressed air.

11
 CHAPTER 3

PROBLEM IDENTIFICATION

 A continuous air leak from the small vent hole in the regulator bonnet
indicates a leaky main bonnet or diagram. Repair parts should be ordered at
once and the regulator should be scheduled for repair. Overhaul kits with
diaphragm and seals are available for most standard regulators.
 Operate the compressors at as low a pressure as possible. Do recall,
however, that operating below the rated pressure of air treatment may de-
rate the air treatment. Excess pressure requires additional compressor power
as well as intensifying leaks and causing legitimate users to use excess air.
 One of the most common problems experienced in a compressed air system
is low pressure or perceived low pressure. Symptoms can include machinery
faults, inability of air cylinders to apply necessary force, or inadequate
torque on an air tool..

12
 CHAPTER 4
OBECTIVES

 The main objective is to develop compressed air engine which can be run by
the compressed air. Main advantage of compressed air engine is that no
hydrocarbon fuel required means no combustion process
 The main objective is to develop compressed air engine which can be run by
the compressed air. A four stroke single cylinder conventional engine can be
run on compressed air with a few modifications. Main advantage of
compressed air engine is that no hydrocarbon fuel required means no
combustion process. Our environment must be protected against various
contaminations produced by vehicles driven on I.C. engine which produces
some of most adverse environment effects. For example, Nitrogen oxide
(NOX) after oxidation forming nitric acid, contributes to acid rain which
causes severe damage to environment. Nevertheless,
 the compressed air technology will contribute to reduce air pollution and
tend to zero pollution level and promoting great environment. This is
because in compressed air engine air is used as fuel and exhaust is also in the
form of air. There are several technical benefits of using this engine, like as
no combustion inside cylinder, working temperature of engine is very close
to ambient temperature. This in turn results in smooth working of engine,
less wear and tear of engine components. There is one more technical benefit
that there will not be any need for installing cooling system or complex fuel
injection system, etc. These benefits result simple design, simple
construction and less weight. Thus compressed air technology satisfies
present demand and can prove to be future transport medium.

13
CHAPTER 5

14
WORKING PRINCIPLE

A compressed air engine is a type of engine in which mechanical work by

expanding compressed air. Pneumatic engine generally convert compressed air
energy to mechanical work either into linear motion or rotary motion. If
compressed air is transferred into the on board storage tank, it is slowly released to
power the transport vehicle’s pistons. The motor then converts the air power into
mechanical power

The slider crank mechanism is used in this project The working principle
of pneumatic cylinder. ... The gas is compressed in the cylinder of the compressor
to increase the pressure. Pneumatic cylinder is composed of cylinder, end cover,
piston, piston rod and seal. The piston is lubricated by the oil mist in the
compressed air when the cylinder works

The lever control valve allows the compressed air from the compressor
to the pneumatic cylinder to extend it. This linear activation obtained is converted
into half the rotation of crank shaft and its next half rotation is obtained by
retraction of the pneumatic cylinder

Fig. 5.1 crank and cylinder work

15
WORKING OF PNEUMATIC ENGINE:

Fig. 5.2 Flow Chart

16
 CHAPTER 6
LINE DIAGRAM & DESIGN CALCULATION

17
 LINE DIAGRAM OF THE MODEL:

Fig. 6.1 Line Diagram

Line diagram of pneumatic engine and it’s have a various components

18
CAD MODELLING :

Fig. 6.2

Fig. 6.3 Top view

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Fig. 6.4 prototype

Fig. 6.5

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 DESIGN CALCULATION

DESIGN OF PNEUMATIC CYLINDER:

 Bore Dia = 25mm

 Length of Stroke = 100mm
 Max pressure = 0.1-0.7 Mpa

Product Name Air Cylinder

Model MAL25x100
Action Type Double Action
Material Aluminum Alloy
Bore 25mm
Stroke 100mm
Max Pressure 1MPA
End Cap Thread M22x1.5
Rod Thread Diameter M10x1.25
Air Hole Diameter PT1/8
Quantity 1pc
Table. 6.1

The formula for the air consumption of a double-acting pneumatic cylinder is

as follows:
 A = Piston Area (Square Inches)
 R= Rod Area (Square Inches)
 S = Stroke (Inches)
 C = Cycles per Minute.
 CFM (Cubic Feet per Minute) = [(2*A - R) x S x C] / 1728
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DESIGN OF BALL BEARINGS:

PRINCIPAL DIMENSIONS
Inside diameter: = 17mm
Outside diameter: = 40mm
Width: = 12mm

BASIC LOAD RATINGS

Dynamic: = 9.95kn
Static: = 4.75kn

SPEED RATINGS
Reference speed: = 38000 r/min
Limiting speed: = 19000 r/min

DIMENSIONS mm
d1: = 24.5
d2: -
D2: = 35
r1,2 min: = 0.6

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 CHAPTER 7
DESCRIPTION OF COMPONENTS

23
LIST OF COMPONENT:

 Pneumatic cylinder
 Air compressor
 Lever control valve
 Crank shaft
 Connecting rod
 Hoses
 Connecters
 Roller bearings
 Pressure Regulator

PNEUMATIC CYLINDER:

Fig. 7.1 Pneumatic Cylinder:

24
 Double-acting cylinders (DAC) use the force of air to move in both extend
and retract strokes. They have two ports to allow air in, one for outstroke and one
for instroke. Stroke length for this design is not limited, however, the piston rod is
more vulnerable to buckling and bending. Additional calculations should be
performed as well

Pneumatic actuators are the devices used for converting pressure energy of
compressed air into the mechanical energy to perform useful work. In other words,
Actuators are used to perform the task of exerting the required force at the end of
the stroke or used to create displacement by the movement of the piston. The
pressurised air from the compressor is supplied to reservoir. The pressurised air
from storage is supplied to pneumatic actuator to do work. The air cylinder is a
simple and efficient device for providing linear thrust or straight line motions with
a rapid speed of response. Friction losses are low, seldom exceeds 5 % with a
cylinder in good condition, and cylinders are particularly suitable for single
purpose applications and /or where rapid movement is required. They are also
suitable for use under conditions which preclude the employment of hydraulic
cylinders that is at high ambient temperature of up to 200 to 250 Their chief
limitation is that the elastic nature of the compressed air makes them unsuitable for
powering movement where absolutely steady forces or motions are required
applied against a fluctuating load, or where extreme accuracy of feed is necessary.
The air cylinder is also inherently limited in thrust output by the relatively low
supply pressure so that production of high output forces

25
AIR COMPRESSOR:

Fig. 7.2 Air Compressor:

An air compressor is a device that converts power (using an

electric motor, diesel or gasoline engine, etc.) into potential energy stored in
pressurized air By one of several methods, an air compressor forces more and more
air into a storage tank, increasing the pressure. When tank pressure reaches its
engineered upper limit, the air compressor shuts off. The compressed air, then, is
held in the tank until called into use.[1] The energy contained in the compressed air
can be used for a variety of applications, utilizing the kinetic energy of the air as it
is released and the tank depressurizes. When tank pressure reaches its lower limit,.

26
LEVER CONTROL VALVE:

Fig.7.3 Lever Control Valve

Directional Control Valves (DCVs) are one of the most fundamental

parts of hydraulic and pneumatic systems. DCVs allow fluid flow (hydraulic
oil, water or air) into different paths from one or more sources. DCVs will usually
consist of a spool inside a cylinder which is mechanically or electrically actuated.

CRANK SHAFT:

The crankshaft, sometimes casually abbreviated to crank, is the part of an

engine which translates reciprocating motion into rotary motion or vice versa.
Crank shaft consists of the shaft parts which revolve in the main bearing, the crank
pins to which the big ends of the connecting rod are connected, the crank webs or
cheeks which connect the crank pins and the shaft parts.

27
 Fig.7.4 Crank Shaft

HOSES:

Fig. 7.5 Hoses

28
 THE basic function of pneumatic tubing and hose is to convey pressurized
air to actuators, valves, tools and other devices.. Pneumatic hose generally consists
of an inner tube, one or more layers of reinforcing braided or spiral-wound fiber,
and an outer protective cover.

CONNECTERS :

Fig. 7.6 Connecters

Pneumatic fittings are parts used to connect sections of pipe, tube, and
hose in pneumatic (pressurized gas) systems. Compared to
hydraulic fittings, pneumatic fittings are typically characterized by tighter seals and
lower pressure requirements.

29
ROLLER BEARINGS :

Fig. 7.7 Roller Bearings

The concept behind a bearing is very simple: Things roll better than they
slide. The wheels on your car are like big bearings. If you had something like skis
instead of wheels, your car would be a lot more difficult to push down the road.
That is because when things slide, the friction between them causes a force that
tends to slow them down. But if the two surfaces can roll over each other, the
friction is greatly reduced. Bearings reduce friction by providing smooth metal
balls or rollers, and a smooth inner and outer metal surface for the balls to roll
against. These balls or rollers "bear" the load, allowing the device to spin smoothly

As one of the bearing races rotates it causes the balls to rotate as well.
Because the balls are rolling they have a much lower coefficient of friction than if
two flat surfaces were rotating on each other.

30
PRESSURE REGULATOR:

Fig.7.8 Pressure Regulator

A pressure regulator is a control valve that reduces the input pressure of a fluid to a
desired value at its output

31
 CHAPTER 8

FABRICATION EQUIPMENT

32
FABRICATION EQUIPMENT:

 Welding Equipment
 Metal cutting machine
 Gas cutting
 Hand grinding machine

WELDING EQUIPMENT:

Fig. 8.1 Arc welding machine

The direction of current used in arc welding also plays an important role in
welding. Consumable electrode processes such as shielded metal arc welding and
gas metal arc welding generally use direct current, but the electrode can be charged
either positively or negatively

33
METAL CUTTING MACHINE:

Grinders and grinding machines use an abrasive that is bonded to a wheel,

belt or disc to remove material and improve surface finish.

Fig. 8.2 Cutting Machine

34
CHAPTER 9

35
FABRICATION MODEL ASSEMBL

Fig.9.1 assembled model

Fig.9.2 side view

36
CHAPTER 10

37
 CONCLUSION

The model designed by us is a small scale working model of the

compressed air engine. When scaled to higher level it can be used for driving
automobiles independently or combined (hybrid) with other engines like I.C.
engines.

Main advantages of Compressed Air Engine (C.A.E.) are:

1. Zero emission
2. Use of renewable fuel.
3. Zero fuel cost (the cost is involved only in the compression of air)

It’s important to remember that while vehicles running on only

compressed air might seem like a distant dream, but they still have public interest
due to their environmental friendly nature. Compressed air for vehicle propulsion
is already being explored and now air powered vehicles are being developed as a
more fuel-efficient means of transportation. This Internatio Compressed Air
Vehicle: A Review 13 paper explores the effective application of pneumatic
power. Pneumatic vehicle will replace the battery operated vehicles used in
industries. Pneumatic powered vehicle requires very less time for refueling as
compared to battery operated vehicle

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 FABRICATION COST ESTIMATION

MATERIAL COST:

S.NO MATERIAL QUANTITY COST

1 Pneumatic cylinder 1 800

2 Lever control 1 750

valve
3 FR Unit 1 850

4 Hose & connecters As requried 400

5 Fabrication metal As requried 900

6 Bearings 2 300

TOTAL 4000
Table. 10.1

MAHCHINING COST:

S.NO MACHINING COST

1 Welding 400

2 Drilling 100

3 Cutting 150

TOTAL 650
Table. 10.2

39
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