Fabrication of Compressed Air Vehicle

At present, Global Warming is a main problem we are facing, and automobiles are increasing day by day. They are emitting harmful gases which are responsible for greenhouse effect. Due to Non Renewable energy crisis, many companies and manufacturers are taking interest to reduce these crises by using

Project Title

Fabrication of Compressed Air Vehicle

Project Area of Specialization

Mechatronics Engineering

Project Summary

At present, Global Warming is a main problem we are facing, and automobiles are increasing day by day. They are emitting harmful gases which are responsible for greenhouse effect. Due to Non Renewable energy crisis, many companies and manufacturers are taking interest to reduce these crises by using alternate energy sources. We know that air is nonflammable and does not produce any type of pollution. In this review we are considering to fabricate a Compressed Air Vehicle where air is used as an alternate energy source. The main aim of this vehicle is to get zero emission, economical, light weight and can control energy crisis. The scope of this vehicle is that we can use in torpedoes locomotives as well as light industries. MDI (Motor Development International) makes vehicles such as busses or cars using compressed air technology.

Project Objectives

• To fabricate a model of vehicle which runs on compressed air
• Fabricated engine is to be tested to checkout its working conditions.
• An air driven engine uses the epansion of compressed air to drive thhe piston of the engine.
• In this four stroke SI engine is altered to work as a compressed air engine (CAE).
• Compare with other electric and fuel vehicles with respect to their cost, emission, structure design, efficiencies, millage and other factors
• The compressed air technology will contribute to zero pollution level.

Project Implementation Method

                       In this project we fabricate a compressed air vehicle by using already fabricated engine.  Initially we researched on design and fabrication of Compressed Air Vehicles. We studied about the history of CAV and its latest innovation and progress by different engineers and scientists. We designed 3D model of a CAV and solved different design calculations and analyse the expected outcomes. Fabricated engine is to be tested to checkout its working conditions. Major components used in CAV are cylinders, body frame, compressor, regulator valve, brake system, pressure valves, hoses, tyres.

                        A compressor and cylinders (storage of compressed air) are to be required for a constant supply of compressed air. Regulator and pressure guages are used to regulate the air pressure and indicate the output pressure and cylinder pressure. Special Hoses are used for  the supply of compreesed air to the engine. 

                       When the accelerator pedal is pressed, air is passed through  a regulating valve to the cylinder.. Forward and backward movement of the piston is connected to the crank shaft. Hence linear movement of the piston is converted into a rotary motion by means of chain and sprocket which is connected with the rear axle. Thus the vehicle attains its motion.

                       Finally it's mileage and cost will be compared with the convention engines available in market. It will also be compared elite with electric vehicles in term of energy consumption & mileage.
 

Benefits of the Project

• It uses no gasoline or other bio-carbon based fuel.
• Reduction or elimination of hazardous chemicals such as gasoline or battery acids/metals.
• Pollution free and easy to manufacture.
• Very low cost and fuel efficient (compressed air).
• Low maintenance cost
• compressed air vehicle is that no hydrocarbon fuel required means no combustion process.
• Stored compressed air devices have a low energy density compare to hydrocarbon fuels or hydrogen devices (e.g fuel cells).
• Compressed air technology reduces the cost of vehicle production by about 20%, because there is no need to build a cooling system, fuel tank, spark plugs or silencers. 
• Lighter vehicles would mean less abuse on roads, thus, resulting in longer lasting roads
• When the air is being compressed at reasonable speeds, it heats up. The heat given off during compression could be reclaimed for space heating or water heating, or used in a stirling engine.
• Compressed-air vehicles are unconstrained by the degradation problems associated with current battery systems.
• The tank may be able to be refilled more often and in less time than batteries can be recharged, with refueling rates comparable to liquid fuels. 
• Compressed-air tanks can be disposed of or recycled with less pollution than batteries.
• The tanks used in a compressed air motor have a longer lifespan in comparison with batteries, which, after a while suffer from a reduction in performance. 

Technical Details of Final Deliverable

                           The speed of the modified air engine was measured with the help of tachometer at constant air pressure ranging from 2 to 6 bars.It has been found that if the cam lobes in conventional engine of 4-stroke engine is modified and timing valve ratio is changed then the conventional engine can be converted into air engine. Thus, the performance of compressed air engine mainly influenced by air supply pressure. The prototype of compressed air engine has good performance under low speed. Air powered vehicle is a realization of latest technology in automobile field tend to healthier environment.

Table: Engine Speed at different values of intake pressure at load condition.

Structural Analysis of Vehicle Frame
                          Considering the vehicle base frame, analysis is conducted to determine the load bearing capacity of the frame at various points and its behavior when subjected to bending loads. Pulling force is calculated using the equation

Design Calculations

Piston Dia = D1= 47mm
Rod Dia = D2= 41.4mm
Revolution = N = 250 rpm
Rider Weight = 80kg
Vehicle weight = 50kg
Cylinder weight = 40kg
Total weight = 170kg
Pressure = 6 bar
Wheel Dia = d = 0.414 m
Cylinder Thrust
F = P*(3.14*D1^2)/4
F = 600000*(3.14*(0.047)^2)/4
F = 1040.43 N
Pulling Force
F = P*(D1^2-D2^2)/4
F = 600000*(0.047^2 ? 0.0414^2)/ 4
F = 74.256 N
Speed 
v = (3.14*d*N)/60 m/s
=(3.14*0.414*250)/60 m/s
v= 19.49 km/h 
Acceleration 
a = v/t
= 5.4/10
=0.54 m/s^2
Force 
F = ma
=170*0.54
= 91.8 N
Rolling Resistance
Fr=µ*mg
= 0.02*170*9.81
Fr=33.35 N 
Total Force
Ft = F + Fr
= 33.35 + 91.8 = 125.15 N 
Power required
P=Ft*v
= 125.15*5.4
= 675.81 W
Torque required
T = Ft*r = 125.15*0.207 = 25.9 Nm

These are the major parameters required to drive the vehicle

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Final Deliverable of the Project

Hardware System

Core Industry

Manufacturing

Other Industries

Transportation

Core Technology

Clean Tech

Other Technologies

Sustainable Development Goals

Affordable and Clean Energy, Industry, Innovation and Infrastructure, Climate Action

Required Resources

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