COMPLEX ENGINEERING

PROBLEM
Manufacturing Process II

Group Member:
Mehmood Masood 18-ME-01

Farrukh Shahzad 18-ME-34

Shazil Shamim 18-ME-61

Hannan Shaukat 18-ME-01

Contents
Airbag:.........................................................................................................................................................1
Types of Airbags:.....................................................................................................................................1
 Frontal Airbags.............................................................................................................................1
 Knee Airbags................................................................................................................................1
 Side Curtain Airbags.....................................................................................................................1
 Side Torso Airbags.......................................................................................................................1
 Seatbelt Airbags...........................................................................................................................1
Materials:....................................................................................................................................................2
Propellant:...................................................................................................................................................2
Air bag:........................................................................................................................................................2
Final assembly of air bag module:...............................................................................................................3
Inflator assembly:........................................................................................................................................3

(a)

Airbag:
An airbag is an inflated support meant to protect vehicle occupants (cars, trucks, etc.) from
serious harm in the event of a collision. An inflated restraint that includes an air bag is
sometimes known as an air bolster restraint system (i.e., ACRS) or the air bag supplementary
restraint system (i.e., SRS) As a result, the air bag is intended to supplement the protection
offered by seat belts.

Types of Airbags:
The types of airbags that are installed in a vehicle are determined by the manufacturer.
Airbags are classified into four types: frontal airbags, knee airbags, curtain airbags, and
seatbelt airbags.
 Frontal airbags are in the steering wheel or the front right dashboard and deploy in mild
to severe frontal or near-frontal collisions.
 Knee Airbags: The knee airbag is located beneath the steering wheel and is designed to
protect the driver's knees and legs.
 Side Curtain Airbags: This sort of airbag runs along the interior's left and right sides.Side
Torso airbags: These airbags typically extend from the vehicle's left and right front seats.
  Seatbelt Airbags: In the event of a collision, certain vehicles include a tubular airbag that
releases from within the seatbelt.

Whether one or more of the above airbags deploy depends on the collision. For
example, in low-speed offset frontal crashes, you might see the deployment of
airbags near the front-seat passenger, but not near the driver. In side impacts,
the crash sensors might signal to deploy the passenger side airbags, but not the
knee airbags in the driver’s seat. The type of airbag deployment depends on
the collision and what crash sensor signals the airbag system to deploy.

Materials:
Crash sensors, an air bag module, a steering wheel connection coil, a diagnostic monitoring unit,
and an indication bulb comprise an airbag system.
An air bag module is made up of three key components: the inflator, the air bag, and the
propellant. An air bag is made of woven nylon fabric and comes in a wide variety of sizes and
forms depending on the vehicle. The driver's side air bag material has a heat shield covering to
protect it from burning during deployment, especially near the inflator assembly.
(b)

Airbag manufacturing entails three separate assemblies that come together to make the
completed airbag module, product. The propellant must be manufactured, the inflator
components constructed, and the airbag cut and stitched. Few manufacturers buy pre-made
components like airbags or initiators and then build the entire airbag module.

Propellant:
1. The propellant is made up of NaN3 (sodium azide) combined with an oxidizer and a
chemical that aids in the burning of the NaN3. NaN3 is received from outside suppliers
and examined to ensure compliance, following which it is stored in a secure location until
needed. Simultaneously, oxidizer is received from outside vendors, examined, and stored.
Different oxidizers are used by different manufacturers.

2. Retrieved from storage Because of the risk of explosions, NaN3 and the oxidizer are
carefully combined under debased computerized process control. The powder is
 processed in segregated bunkers. If safety sensors detect a spark, high-speed deluge
systems would flood whole rooms with water. Because manufacturing takes place in
multiple redundant smaller facilities, if an accident happens, production will not be
stopped down; rather, it will be reduced.

3. The propellant mixture is then stored once it has been blended. The propellant mixture is
subsequently compressed into disc or pellet form using presses.

Air bag:
Outside vendors supply the woven nylon air bag fabric, which is tested for material problems.
The air bag cloth is then die cut to the appropriate shapes and sewed inside and externally to
unite the two sides properly. After the air bag has been stitched. It is inflated and examined for
any seam flaws.

Final assembly of air bag module:

The air bag assembly is then attached to the inflator assembly for testing. The air bag is then
folded, and the breakaway plastic home pad cover is attached. Finally, the assembled module is
examined and tested.
Com starch or talcum powder is also used to coat the air bag; either ingredient prevents the cloth
from adhering together and makes assembly simpler. Newer silicone and urethane coated air bag
materials need little to no heat shield coating. Although com starch or talcum powder will most
likely continue to be used as a processing aid.
The inflator body or canister is made of cast aluminium or pressed stainless steel. A filter
assembly made of stainless-steel wire mesh with ceramic material sandwiched in between is
housed inside the inflator canister. The filter assembly is wrapped with metal foil whenever the
inflator is installed to maintain a seal that prevents propellant contamination.

Inflator assembly:
1. Outside suppliers are allowed and examined for inflator components such as the stainless-
steel wire filter assembly, metal canister meshes with ceramic material within, and the
initiator (igniter). Following that, the components are put together on a highly automated
assembly line.
2. The inflator assembly is made up of the inflator sub assembly, an initiator, and
propellant. While friction inertial, laser welding (using carbon dioxide gas) is used to
attach SS (stainless steel) inflator sub-assemblies. Welding is used to attach the sub-
assemblies of aluminium inflators. Friction inertial welding comprises rubbing two
metals together until the surfaces get hot enough to connect. Laser welding entails using
laser beams to weld the assemblies together, whereas laser welding entails utilising laser
beams to fuse the assemblies together.
3. The inflator assembly is then tested and stored until it is needed again.