Design and Manufacturing of Automobile Vehicle Safety with Pneumatic Bumper

Design and Manufacturing of Automobile Vehicle Safety with Pneumatic Bumper Page No. …..
copyright @ SME 2016 national (Indian)
Paper Name
Design and Manufacturing of Automobile
Vehicle Safety with Pneumatic Bumper
PAPER SUBMITTED BY,
Mr. SHAIKH PARVEZ LATIF
{B.E. MECHANICAL, PUNE}
(Nandgaon, Nashik, Maharashtra, India, PIN: 423106.)
-: Contact :-
Mob.: +91 9822706978
Email ID- “ shaikhpl@gmail.com ”
YEAR OF PAPER SUBMISSION
2015-2016

CONTENTS
Sr.No. Content Page no.
1.0 Abstract 01
2.0 Introduction 02
3.0 Problem statement 03
4.0 Objectives 04
5.0 Future scope 05
6.0 Literature review 06
6.1 Safety system 06
6.2 Cushion (energy absorption) 06
6.3 Support (load distribution) 06
6.4 Beam design 07
6.5 Bumper-mounted sensors and/or bumper airbags 07
7.0 Components of project setup 08
7.1 Pneumatic system 08
7.2 Limit switch 08
7.3 IR (infrared) proximity sensor 09
7.4 Electronic relay circuit 10
7.5 Pneumatic power 10
7.6 Braking system 11
8.0 Construction and working 12
9.0 Merits and demerits 13
10.0 Te Technical data 14
11.0 Pneumatic unit 14
12.0 Testing and analysis 15
13.0 Research paper used 16
14.0 References 17

LIST OF FIGURES
Fig. No. Name of figure Page No.
01 Direction of chances Automobile vehicle damage. 03
02 Limit Switch 08
03 IR Proximity Sensor 09
04 Working of IR Proximity Sensor 09
05 Electronic Relay Circuit 10
06 Pneumatic Power System. 10
07 Pneumatic Braking System. 11
08 Experimental Setup 12

1.0 ABSTRACT
The technology of pneumatics plays a major role in the field of automation and modern
machine shops and space robots. The aim is to design and develop a control system based
intelligent electronically controlled automotive bumper activation and automatic braking system
is called automatic pneumatic bumper and break actuation before collision. This project consists
of transmitter and receiver circuit, control unit, pneumatic bumper system and pneumatic
braking system. The is sensor senses the obstacle. There is any obstacle closer to the vehicle
(within 3 - 4 feet); the control signal is given to the bumper activation system and also
pneumatic braking system simultaneously. The pneumatic bumper and braking system is used to
product the man and vehicle. This bumper and braking activation system is only activated the
vehicle speed above 30 - 40 km per hour. This vehicle speed is sensed by the proximity sensor
and this signal is given to the control unit and pneumatic bumper and braking activation system.
In the design of an automobile, a most important task is to minimize the occurrence and
consequences of automobile accidents. Automotive safety can be improved by "active" as well
as "passive" measures. Active safety refers to technology which assists in the prevention of a
crash. Passive safety includes all components of the vehicle that help to reduce the
aggressiveness of the crash event. Crash protection priorities vary with the speed of the car
when crash occurs.

2.0 INTRODUCTION
The purpose of the front/rear bumper system is:
1. To absorb energy at the start of a crash and to guide the remaining crash forces into
the rest of the body structure.
2. At low and medium speed: to minimize the damage of the vehicle in order to reduce
insurance cost.
3. At higher speed: to guide the crash forces into the body structure in such a way that
the probability for a disintegration of the body structure is low and the survival of the
occupants is ensured.
4. To meet the legal (as well as any higher, OEM-specified) requirements regarding the
energy absorbing ability.
Another important function of the front/rear bumper system is the towing
function. This function requires both stiffness and strength. Bumper design concepts
have changed drastically over the last 20 to 30 years. In the past, cars were equipped
with bulky, protruding bumpers to comply with the bumper standards of the 1970s
and early 1980s. More demanding safety regulations and different styling concepts
have resulted in new designs. Styling fashion has drastically changed the visual
appearance of the bumpers. Whereas in the past, bumpers also served as a bright
shiny decorative design element, they are now predominately concealed by a painted
thermoplastic fascia. Since the late 1980s, most bumpers fascia systems are colour
coordinated with the body. {1}.
Then we develop another safety future in vehicle bumper system the aim is to
design and develop a control system based an intelligent electronically controlled
automotive bumper activation system is called “automatic pneumatic bumper”.
There is any obstacle closer to the vehicle (within 4 feet), the control signal after
pressing the extra break switch is given to the bumper activation system.
The pneumatic bumper system is used to product the man and vehicle. This
bumper activation system is only activated the vehicle speed above 40-50 km per
hour. This vehicle speed is sensed by the proximity sensor and this signal is given to
the control unit and pneumatic bumper activation system is activated.

3.0 PROBLEM STATEMENT
In conventional vehicles there are different mechanism operated for braking system like
hydraulic, pneumatic, air, mechanical, etc. But all these braking mechanisms receive the signal
or input power directly from the driver so it totally manual operated. When the driver saw the
obstacle or any vehicle in front of his driving vehicle, he was irritated or becomes mazy. Due to
this the driver fails to give the proper input to braking system and proper working is not occurs.
Also the driver may not able to pay the full attention during night travelling so there are many
chances to accidents. After the accident occurs, there is no any provision to minimize the
damages of vehicles. In currently used vehicles generally bumpers used are of rigid types. These
bumpers have specific capacity and when the range of the accidental force is very high then the
bumpers are fails and these force transferred towards the passengers. So this system never
reduces the damage of both vehicle and passengers. Following fig. shows the Direction of
chances of Impact by percentages and there is 21% of chances Automobile vehicle damage from
frontal area. So, that’s why we worked on Automobile vehicle safety with pneumatic bumper.
Fig.01. Direction of chances Automobile vehicle damage.

4.0 OBJECTIVE
To overcome these unwanted effects we have to Design and Manufacturing of
Automobile Vehicle Safety with Pneumatic Bumper which have following objectives:
1) To increase the sureness of braking Application.
2) To increase the response time of braking system.
3) To improve the pre-crash safety.
4) To avoid the percentage of passenger injury by using external vehicle safety.
5) To reduce the requirement of internal safety devices like air bags, that is more costly.

5.0 FUTURE SCOPE
The future scope for the pneumatic bumper mechanism is that it will be available at low
cost and can be provided for the medium scaled vehicles without raising the cost. It will
increase the sureness of braking Application also will increase the response time of braking
system .It will also reduce the requirement air bags for inner safety which costs very high while
manufacturing and also during rewrapping after the damage .

6.0 LITERATURE SURVEY
6.1 SAFETY SYSTEM -
Automobile safety is the study and practice of design, construction, equipment and
regulation to minimize the occurrence and consequences of automobile accidents. Road traffic
safety more broadly includes roadway design. The aim is to design and develop a control system
based on pneumatic breaking system of an intelligent electronically controlled automotive
braking system. Based on this model, control strategies such as an 'antilock braking system'
(ABS) and improved manoeuvrability via individual wheel braking are to be developed and
evaluated.
6.2 CUSHION (ENERGY ABSORPTION) -
The cushion function of the bumper in a pedestrian impact is directly related to the
acceleration impact criterion. It is intended to reduce the severity of bone fractures in a
pedestrian impact. This function is not entirely dissimilar from the traditional function of a
bumper system (absorbing energy of a vehicle impact). But, there are two key differences: the
impact energy and the acceptance criteria. Impact Energy A vehicle-to-vehicle impact requires a
local energy absorption ‘density’ approximately double that of the pedestrian impact, as can be
seen through this brief analysis:
6.3 SUPPORT (LOAD DISTRIBUTION) -
The support function of the bumper system is directly related to the knee bend angle
criterion illustrated. It is intended to reduce the risk of severe knee joint injuries such as
ligament ruptures and intra-articular fractures. The goal is to provide enough support below
and/or above the main bumper to limit the bending moment at the knee joint during an impact.
This situation is complicated by two vehicle design requirements:
• The vehicle damageability standard for bumpers requires the front bumper to be located
at approximately the same height as the pedestrian ‘leg-form’ knee. So without other
support, the greatest bending moment would occur at the knee. This standard also
mandates no damage to other vehicle components, limiting their location.
• The ground clearance and approach angle requirements limit how low to the ground any
components can be located. The goal in the design of bumper components to support the
lower limb during a pedestrian impact is to limit the ‘leg-form’ bending without either,

(i) Sacrificing vehicle damageability,
(ii) Violating vehicle approach angles. The literature and patent review identified
different approaches to meet this goal. As above, these are summarized in order of
decreasing popularity, as measured by the number of patents describing each solution.
An example patent is listed for each.
6.4 BEAM DESIGN -
The design of the bumper beam in a beam-absorber system (traditional passenger car)
has also received some attention. In particular, there are several proposals to change the shape of
the face of the beam to eliminate foam ‘bottoming-out’ and reduce leg form knee bending. In
addition, moulded plastic absorbers often require additional attachment points on he face of the
beam. This represents a common though minor design trend that is really just part of good
design practice.
6.5 BUMPER-MOUNTED SENSORS AND/OR BUMPER AIRBAGS -
The major benefit of this approach is that protecting for pedestrian impact would result
in virtually no change to vehicle styling. In addition, any type of bumper system could be used
with an airbag cover – the energy absorption of the bumper is irrelevant. The key disadvantages
are cost, durability, and feasibility of the system. Sensors and airbags are much more expensive
than most components in other proposals, and their durability outside the vehicle is unknown. In
addition, no sensor has yet demonstrated the performance required to deliver this system. As
these technologies were not reviewed in-depth in this study, insufficient data exists to predict
how likely implementation will be. Major patent activity is on-going in the supporting
technological areas, but the remaining technical hurdles and costs are significant. In the author’s
opinion, implementation will likely be limited to styling-critical vehicles. {2}.
Once the preliminary simulation model has been thoroughly benchmarked and existing
control system strategies evaluated, an audit of the technology used is to take place and this will
provide a basis for comparison of iterative technologies / techniques.
The final phase of the new modern vehicle shall include
• Development of improved ABS control systems
• Development and assessment of an electro-hydraulic-BBW (EH-BBW) system
• Individual wheel braking combined with traction control
• Assessing sensor failure and fault tolerant control system design.

7.0 COMPONENTS OF PROJECT SETUP
7.1 PNEUMATIC SYSTEM -
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. 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. The compressibility of the air was first investigated by Robert Boyle in
1962 and that found that the product of pressure and volume of a particular quantity of gas.
7.2 LIMIT SWITCH -
A limit switch is an electromechanical device that consists of an actuator mechanically
linked to a set of contacts. In electrical engineering a limit switch is a switch operated by the
motion of a machine part or presence of an object. They are used for control of a machine, as
safety interlocks, or to count objects passing a point. When an object comes into contact with
the actuator, the device operates the contacts to make or break an electrical connection. Limit
switches are used in a variety of applications and environments because of their ruggedness,
ease of installation, and reliability of operation. They can determine the presence or absence,
passing, positioning, and end of travel of an object. They were first used to define the limit of
travel of an object hence the name “Limit Switch”.
Fig.02. Limit Switch.

7.3 IR (INFRARED) PROXIMITY SENSOR -
The setup of IR sensors module that is to be used on the vehicle’s frontal bumper area to
detect before crash situations which is obtained at receiver of IR (infrared) sensor in terms of
Current & voltage. The signal can be smoothened using to start the automatic safety vehicle
system to absorb and avoid unnecessary crash impact event. {3}.
Fig.03.IR Proximity Sensor.
Fig.04.Fig a,b,c shows how IR sensor
works

Automobile
frontal area with
IR sensor
Relay Circuit
Limit Switch &
Power Supply
Pnumatic System
Bracking System
7.4 ELECTRONIC RELAY CIRCUIT -
Circuit is activated only when there is object sense by IR sensor which is present on
front vehicle at speed of automobile vehicle is above in the range of 45 km/h. At this point of
time, the vehicle is traveling in a straight line. The speed of the vehicle has to be regulated
manually to maintain safety. Hence the input of the speedometer is compared with the ideal
value of the speed. If the speed is less than 45 km/h the relay circuit is not active.
Fig.04. Electronic Relay Circuit.
7.5 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.
Fig.05. Pneumatic Power System.

7.6 BRACKING SYSTEM -
In Automobile Vehicle, The mechanism is often a hand-operated lever on the floor on
either side of the driver, or a pull handle located below and near the steering wheel column, or a
(foot-operated) pedal located far apart from the other pedals. Although sometimes known as an
emergency brake, using it in any emergency where the footbrake is still operational is likely to
badly upset the brake balance of the car and vastly increase the likelihood of loss of control of
the vehicle, for example by initiating a rear-wheel skid. Additionally, the stopping force
provided by using the handbrake instead of or in addition to the footbrake is usually small and
would not significantly aid in stopping the vehicle, again because it usually operates on the rear
wheels; they suffer reduced traction compared to the front wheels while braking. The most
common use for an automobile emergency brake is to keep the vehicle motionless when it
is parked, thus the alternative name, parking brake. Car emergency brakes have
ratchet locking mechanism that will keep them engaged until a release button is pressed. On
vehicles with automatic transmissions, this is usually used in concert with a parking pawl in the
transmission. {4}.
Fig.06. Pneumatic Braking System.

8.0 CONSTRUCTION AND WORKING
Compressed air is used as force medium of this project operation. This compressed air
can be easily taken from the air cylinder of the vehicle used air brake system.The control unit
consists of a relay circuit. It is a photovoltaic sensor switch. It has outputs. The solenoid valve
unit consists of ½ solenoid valves. ½ indicates two ports and one way operation. Compressed
air enters through first solenoid valve and expelled to atmosphere through second solenoid
valve.
Fig.08. Experimental Setup of Automobile Vehicle Safety with Pneumatic Bumper
When driver is in the seat. At that time, the photovoltaic sensor is in open mode. So
current cannot passes to relay circuit through the switch. When driver stands from his seat,
photovoltaic sensor senses and sends electric current to relay circuit. One of the relay output
sends out a voltage to first solenoid valve and now it is in opened position so the compressed air
enters to break chamber. And this time relay stop the current engine coil or motor current.
An additional emergency switch is provided in case of emergency. If the driver needs
bumper, then the emergency switch can be used .It to gives the bottom of break paddle and
provides voltage to the solenoid valve. So the urgent brake is applied .moment gives extra of
paddle these tine limit switch is on and pneumatic bumper is operated forward direction. This
can be used in the case of extreme condition.
The cylinder converts the energy of compressed air into the linear motion. The air enters
the cylinder and pushes the piston from one end of the cylinder to the other. There are two main
types of cylinders-single acting and double acting. A single acting cylinder has only one air
connection while a double acting has two.

9.0 MERITS AND DEMERITS
MERITS
• Quick operation
• Accuracy is more
• It reduces the manual effort.
• Avoid tension of driver
• Emergency parking is available
• Less cost
DEMERITS
• Cylinder stroke length is constant
• Maintenance of the equipment components such as hoses, valves has to
done periodically.

10.0 TECHNICAL DATA
10.1 SOLENOID VALVE
Technical data’s
Size : 0.635x10-2
m
Part size : G0.635x10-2
m
Maximum pressure : 0-10 x10 5
N/m2
Range
Quantity : 2
10.2 HOSES
Technical data’s
Max pressure : 10 x105
N/m
2
Outer diameter : 6mm =6 x 10-3
m
Inner diameter : 3.5mm =3.5 x10-3
m
11.0 PNEUMATIC UNIT
11.1 Technical data
Type of cylinder : Double acting
Cylinder
Type of valve : solenoid valve
Max air pressure : 8 x105
N/m2

12.0 TESTING AND ANALYSIS
It is a simple model. Compressed air at required pressure to stop the vehicle can be taken
from air cylinder of the vehicle, if we used the system in any vehicle that used air brake system
and safety further pneumatic bumper.

13.0 Research Paper Used
Sr.
No
Title Of Paper & Author Page
No.
Objectives Conclusion
1 Applications of Car body
Crash Management Systems
07 Crash Management Bumper systems were originally
installed to protect the engine
and radiator at the front of the
vehicle. A modern front crash
management system, however,
has to fulfill a range of different
additional requirements.
2 Current Trends in Bumper
Design for Pedestrian Impact
Peter J. Schuster
California Polytechnic State
University
12 Bumper Design The deployable approach is to
implement advanced impact
sensors into the bumper and
deploy airbags or structures
over the surface just prior to
impact.
3 Accident Prevention Using
Eye Blinking and Head
Movement
Abhi R. Varma,
Seema V. Arote,
Chetna Bharti,
Kuldeep Singh.
14 Accident Prevention Sensor based control will be the
future of all types of device
control, thus making the
operation so comfortable and
much easier with less human
presence.
4 Automated Vehicle Control
System
M.Habibullah Pagarkar,
Kaushal Parekh,
Jogen Shah,
Jignasa Desai,
Prarthna Advani,
Siddhesh Sarvankar,
Nikhil Ghate.
15 Control System Collision detection and
avoidance systems should
become more commonplace
with the passage of time. People
are living in a networked world
and constantly feel that
they have less time on their
hands.

14.0 REFERENCES
[1] Prof. Mujumdar : “Pneumatics – Study Material”
[2] R. S. Khurmi & I. K. Gupta : “A Textbook or Machine Design”
[3] Prof. H. G. Patil : “Machine Design Data Hand Book (SI Metric)”
[4] Erik Coelingh, etal, “Collision Warning with Auto Brake”, Sweden, ppn: 07-0450.
[5] Dr. Kripal Singh, “Automobile Engineering – Vol. 1”, Standard Publishers Distributors New
Delhi- 110 006
By,
MR. SHAIKH PARVEZ LATIF,
{DME, BE (MECAHANICAL), PUNE, INDIA},
EMAIL ID “ shaikhpl@gmail.com”, MOB NO. +91 9822706978.
THANKS FOR READING……………………………………………………………………………… .

Design and Manufacturing of Automobile Vehicle Safety with Pneumatic Bumper

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