Chapter 1

INTRODUCTION

The use of automobiles has been increasing day-by-day. Humans are

completely reliable on automobiles for transport purpose. In today’s competitive
automobile sector; various automobile industries are competing with each other
in order to win hearts of human. In order to do so the companies are making the
system more effective by improving the safety systems in cars. The more reliable
the system is, more successful the can becomes. After the discovery of wheels
by man, it has been used extensively for variety of purposes. Wheels have
become the vital part of human lives since ages. The effective use of wheels with
more innovative ideas further developed with developing technologies. One
such upcoming technology is automatic air inflation system used in automobiles.
This system is used to maintain the pressure of tires in running condition .The
best application of such automatic air inflation system is in military vehicles.
Military vehicles are supposed to run on various environmental conditions;
where land conditions are continuously changing. Such vehicles are supposed to
be operated in worst conditions such as heavy rainfall, snowfall & deserts. At
such remote places tyre maintenance stations are not available. In such crucial
conditions such systems serves as a boon for the users.

Department of Automobile Engineering, MPTC Kottakkal

1
 Chapter 2
WHAT IS THE CHALLENGE

When not properly inflated, tires flex more under load. This produces
heat and increases rolling resistance, which wastes fuel. Truck tires inflated 10
pounds per square inch (psi) below recommended air pressure levels can
reduce truck fuel economy between 0.5 percent and 1percent. Since the bulk
of the load is carried in the trailer, a 10-psi under inflation in a trailer tire may
have nearly twice the impact on truck fuel economy as the same amount of
under inflation in a drive tire. Heat and stress from improper inflation softens
and deflects tire components, causing faster and more uneven wear, which
shortens the life of the tire. Underinflated tires have more frequent punctures,
increasing the risk of tire failures that could lead to costly road service and loss
of revenue .Despite the importance, a recent survey of combination trucks
found that less than half the tires surveyed were within 5 percent of the
recommended inflation pressure. Another industry survey indicates only 8
percent of truck drivers check tire pressure with a tire gage before each trip.
One reason fleets may find it difficult to keep tires properly inflated is because
truck tires can lose up to 2 psi each month, even if the rim seal and valve stems
are tight. A fleet may not be able to inspect or monitor its’ trailer tires regularly
due to the fact that extended periods of time are spent away from service yards
and because trailers are interchangeable. This places greater responsibility for
checking tire pressure onto drivers.

Department of Automobile Engineering, MPTC Kottakkal

2
 Chapter 3
TIRE-INFLATION BASICS

According to AAA, about 80 percent of the cars on the road are driving with one or
more tires underinflated. Tires lose air through normal driving (especially after hitting pot
holes or curbs), permeation and seasonal changes in temperature. They can lose one or
two psi (pounds per square inch) each month in the winter and even more in the summer.
And, you can't tell if they're properly inflated just by looking at them. You have to use a
tire-pressure gauge. Not only is under inflation bad for your tires, but it's also bad for your
gas mileage, affects the way your car handles and is generally unsafe.

Figure 3.1 Type of tire-inflation

When tires are underinflated, the tread wears more quickly. According to Goodyear,
this equates to 15 percent fewer miles you can drive on them for every 20 percent that
they're underinflated. Underinflated tires also overheat more quickly than properly
inflated tires, which causes more tire damage. The faded areas below indicate areas of
excessive tread wear.

Department of Automobile Engineering, MPTC Kottakkal

3
 Figure 3.2 Front view for types of tire inflation

Because tires are flexible, they flatten at the bottom when they roll. This contact
patch rebounds to its original shape once it is no longer in contact with the
ground. This rebound creates a wave of motion along with some friction. When
there is less air in the tire, that wave is larger and the friction created is greater -
- and friction creates heat. If enough heat is generated, the rubber that holds the
tire's cords together begin to melt and the tire fails. See How Tires Work to learn
more. Because of the extra resistance an underinflated tire has when it rolls, your
car's engine has to work harder. AAA statistics show that tires that are
underinflated by as little as 2 psi reduce fuel efficiency by 10 percent. Over a
year of driving, that can amount to several hundred dollars in extra gas
purchases. This system can be used in any type of tyre either tube or tubeless
tyres and the permanent connection between valve and hoses which is only
meant for tight connection during rotation of tyre; can be removed while
changing a tyre by driver. The valve used with tyre is one way valve so that
inside air should not escape from it.

Department of Automobile Engineering, MPTC Kottakkal

4
 Chapter 4
AUTOMATIC TYRE PRESSURE INFLATION SYSTEM

This system consists of centralized compressor, rotary joint, pressure sensor,

electronic control circuit, battery, wheel and a motor to run that wheel. After getting
ideas of different components needed, we will start making rough design and after that
we will draw a 3-D model in Auto CAD. By referring this 3D model we will buy the
standard component required for the projects. After this we will start manufacturing
work in workshop. Along with this electronics part will also be done. In electronics we
will have to build controller circuit to get signal from pressure. Later testing will be
started for getting various results.

Fig 4.1 Automatic tyre pressure inflation system

Detect when the air pressure in a particular tire has dropped. This means they have
to constantly (or intermittently) monitor the air pressure in each tire. Inflate that tire back
to the proper level - This means there has to be an air supply as well as a check valve that
opens only when needed. The aim of this study is to design and fabricate a system which
reduces human labour and time by eliminating the condition of driver to go to a gas station
or he has to attach a pump manually as physical connection of tyre and pump consumes
more time. Secondly, tyre must not be under inflated nor over inflated i.e. pressure should
be in optimized level as under inflation causes wearing of tyre, consumption of more fuel

Department of Automobile Engineering, MPTC Kottakkal

5
and over inflation causes explosion of tyre. It also gives better mileage and saves both
money and life

Fig 4.2 Section view tyre pressure inflation system

Department of Automobile Engineering, MPTC Kottakkal

6
 Chapter 5
BASIC COMPONENTS

 AIR COMPRESSOR
 WHEEL & TYRE
 FLEXBILE AIR HOSE PIPE
 ROTARTY JOINT
 PRESSURE GAUGE
 CHAIN SPOCKET
 BEARING
 MOTOR
 BATTERY

5.1 AIR COMPRESSOR

The system uses compressor to get the air from atmosphere & to compress it to a required
pressure. A 12V DC compressor has being used in our system. It is perfect for cars, bikes
and inflators. It operates from the cigarette lighter socket of a DC12V.

Figure 5.1 Air compressor

Department of Automobile Engineering, MPTC Kottakkal

7
 In fact, nowadays it is used for such purposes which you would not have
imagined in till the recent past. Basically, a modern air compressor amplifies the
damaging effect of water vapour and airborne particles by virtue of air compressors
lowest prices the compression process. Those days of spending hours pounding
nails to complete a project are over! Sewing They are more susceptible to debris
because
They do not have suction valves. Therefore, if space is not a significant
issue, then there is no need to focus specifically on the direction that the online shop
target air compressors tank lays. Most of these have oil free target pumps which
make them very low maintenance. They can literally help you perform hundreds of
functions and can be taken just about anywhere. For garage purposes, an electric air
compressor will do fine. Plus make sure that any moisture has been removed from
the compressed air source before connecting prices the tool. Air Sander. Brands
names
That would seem more comfortable in the use of a nail gun or jack hammer.
Installing and maintenance takes working knowledge of the application and the
vehicle where it is being installed. The compression that occurs in the air tanks of
your compressors compressor causes moisture to accumulate inside those tanks.
Poly Vinyl Chloride ( PVC) is another synthetic sewing laundry material composed
of thermoplastic lowest polymers which is used to make hose for air compressors
lowest prices special online applications.
Everything seemed just fine. These purchases often entail very few, if any,
guarantees. Owning this kind of compressor sounds fun and helpful but it shop is
first important to consider the things before buying it. This is the volume of the air
that the gas compressor delivers. It is
Proper design has been set up for installing hose and cord. It is ideal for inflating
all vehicle tires and other high-pressure inflatables.

Department of Automobile Engineering, MPTC Kottakkal

8
5.2 WHEEL & TYRE
• Ring Shaped Component Covered The Wheel Rim To Protected

• Better Vehicle Perfomance

• Provide Traction Between Vehicle & Road

• Flexible Cushion Absorbs Shock

Figure 5.2 Wheel & tyre

5.3 FLEXBILE AIR HOSE PIPE

Pneumatic hose generally consists of an inner tube, one or more layers of
reinforcing braided or spiral-wound fiber, and an outer protective cover. In broad terms,
hose is more rugged than tubing but costs more. The air supply and application set a
baseline for the necessary product performance

Figure 5.3 Air hose pipe

Department of Automobile Engineering, MPTC Kottakkal

9
5.4 ROTARTY JOINT

Rotary joint or a Rotary Union is a device that provides a seal between a

stationary passage and a rotating part. Stationary passage may be a pipe or
tubing; whereas rotating part can be a drum, spindle or a cylinder. Thus it
permits the flow of the fluid into and/or out of the rotating part. Generally the
fluids that are used with the rotary joints and rotating unions are steam, water,
thermal oil, hydraulic fluids etc.

Figure 5.4 Rotary joint

A rotary union will lock onto an input valve while rotating to meet an outlet. During
this time the liquid and/or gas will flow into the rotary union from its source and will be
held within the device during its movement. This liquid and/or gas will leave the union
when the valve openings meet during rotation and more liquid and/or gas will flow into the
union again for the next rotation

5.5 PRESSURE GAUGE

A pressure sensor measures pressure of gases or liquids. It generates a signal as a

function of the pressure imposed; in our system such signal is electrical. Pressure sensors
can also be uses to measure other variables such as fluid/gas flow, speed and water level.

Pressure sensors can alternatively be called pressure transducer, pressure

transmitters, pressure senders, pressure indicators, piezometers and manometers among
other names

Department of Automobile Engineering, MPTC Kottakkal

10
 Figure 5.5 Pressure gauge

A pressure sensor measures pressure Pressure sensors can also be uses to measure
other variables such as fluid/gas flow Pressure gauge can be called pressure transducer,
pressure transmitters, pressure senders, pressure indicators ,piezometers and manometers.
A pressure switch is a form of switch that makes electrical contact when a certain pressure
has been reached on its input. This is used to provide on/off switching from a pneumatic or
hydraulic source. The switch may be designed to make contact either on pressure rise or on
pressure fall

5.6 CHAIN & SPOCKET

Sprocket wheel is a profiled wheel with teeth, or cogs, that mesh with a chain,
The name 'sprocket' applies generally to any wheel upon which radial projections
engage a chain passing over it.

Figure 5.6 Chain & spocket

Department of Automobile Engineering, MPTC Kottakkal

11
5.7 BEARING
Journal or plain bearings consist of a shaft or journal which rotates freely in
a supporting metal sleeve or shell. There are no rolling elements in these
bearings. Their design and construction may be relatively simple, but the theory
and operation of these bearings can be complex. This article concentrates on oil-
and grease-lubricated full fluid film journal bearings; but first a brief discussion
of pins and bushings, dry and semi lubricated journal bearings, and tilting-pad
bearings.

Figure 5.7 Bearing

5.8 DC – MOTOR

A DC motor is any motor within a class of electrical machines whereby direct

current electrical power is converted into mechanical power. A DC motor is any motor
within a class of electrical machines whereby direct current electrical power is converted
into mechanical power. Most often, this type of motor relies on forces that magnetic fields
produce. Regardless of the type, DC motors have some kind of internal mechanism, which
is electronic or electromechanical. In both cases, the direction of current flow in part of the
motor is changed periodically.

The speed of a DC motor is controlled using a variable supply voltage or by

changing the strength of the current within its field wind rings. While smaller DC motors
are commonly used in the making of appliances, tools, toys, and automobile mechanisms,

Department of Automobile Engineering, MPTC Kottakkal

12
such as electric car seats, larger DC motors are used in hoists, elevators, and electric
vehicles.

A 12v DC motor is small and inexpensive, yet powerful enough to be used for many
applications. Because choosing the right DC motor for a specific application can be
challenging, it is important to work with the right company. A prime example is MET
Motors, which has been creating high-quality permanent magnet DC motors for more than
45 years. 12v DC motor that MET Motors can assist with include the operating current,
speed, torque, and power. Although a DC motor at this voltage is ideal for many
applications, the company will consider everything prior to making the final
recommendation

Figure 5.8 Dc motor

5.9 BATTERY

An automotive battery is a type of rechargeable battery that supplies electric energy to an

automobile
12v rechargeable battery The cells are connected by short heavy straps from the positive
plates of one cell to the negative plates of the adjacent cell. A pair of heavy terminals, plated
with lead to resist corrosion, are mounted at the top, sometimes the side, of the battery.
Early auto batteries used hard rubber cases and wooden plate separators. Modern units use
plastic cases and woven sheets to prevent the plates of a cell from touching and short-
circuiting.

Department of Automobile Engineering, MPTC Kottakkal

13
In the past, auto batteries required regular inspection and maintenance to replace water that
was decomposed during operation of the battery. "Low-maintenance" (sometimes called
"zero-maintenance") batteries use a different alloy for the plate elements, reducing the
amount of water decomposed on charging. A modern battery may not require additional
water over its useful life; some types eliminate the individual filler caps for each cell. A
weakness of these batteries is that they are very intolerant of deep discharge, for example
when the car battery is completely drained by leaving the lights on. This coats the lead plate
electrodes with sulfate deposits and can reduce the battery's lifespan by a third or more.

Figure 5.9 Battery

Department of Automobile Engineering, MPTC Kottakkal

14
 Chapter 6

WORKING OF AUTOMATIC TYRE PRESSURE

INFLATION SYSTEM

Figure 6.1 Working diagram

Mainly shows the automatic inflation of tires. In this model we use components such as
air compressor, rotary joint, dc motor, battery, hose pipe, chain & sprocket, bearing,
pressure gauge

In this system, compressor is connected to wheel with the help of hoses through a rotary
joint. Pressure sensor and control circuit are connected between wheel and compressor. Set
in the control circuit for automatic start and stop of compressor. Compressor works on 12V
DC supply that is either a car battery or bike or an adapter. A non-return valve is connected
between pressure sensor and compressor, so that the air flow must be unidirectional from
compressor to tyre. When the pressure reduces below the lower limit (20psi) in the tyre
during its rotation, pressure sensor senses this drop and starts the compressor automatically
for the filling air into tyre with the help of control circuit. As soon as the pressure crosses
the set upper limit. Compressor stops working with the help of pressure sensor and control
circuit. In this way, a proper required tyre pressure is maintained.

Department of Automobile Engineering, MPTC Kottakkal

15
 Chapter 7
ADVANTAGES

1- The first main advantage is you don’t have to check tire pressure regularly and so never
want to go for the air filling.
2- The next major advantage is you don’t have to stop in any unsafe area if tire get
punctured, where safety is the matter of concern.
3- The most important is you don’t have to change your tire with another tire which saves
a lot of time and you can utilize that time in reaching to your destination.
4- The cost of system is optimum, but increases safety, comfort and efficiency.
5- The weight of this system is also very less so one can use it in cars, buses, etc.

Department of Automobile Engineering, MPTC Kottakkal

16
 Chapter 8
CONCLUSION

We can conclude that this automatic centralized compressor self-inflating

tyre system ensures that all tyres are always properly inflated and thus improves
the tyre life, safety, reduction of gas mileage and vehicle performance by
supplying air to all tyres via hoses and a rotary joint fixed between wheel spindle
and wheel hub at each wheel whenever there is a pressure drop inside the tyre.

Department of Automobile Engineering, MPTC Kottakkal

17
 BIBILIOGRAPHY

1 Hemant Soni, Pratik Golar, Ashwin Kherde “DESIGN OF AUTOMATIC TYRE

INFLATION SYSTEM” Vol.1,
2 P.Omprakash, T.Senthil Kumar, “M.A.R.S - Mechanized Air Refilling System”.
3 Case study on AUTOMATIC TYRE INFLATION MANAGEMENT.
4 ALEXANDER VARGHESE,
5 John Woodrooffe, “EFFECTS OF TIRE INFLATION PRESSURE”

Department of Automobile Engineering, MPTC Kottakkal

18