DESIGN OF A SMART AIRBAG DEPLOYMENT SYSTEM FOR VEHICLES

DESIGNING MULTI COAL BUNKER LEVEL MONITORING AND RE-FILLING SYSTEM USING A MOBILE PORTABLE
RAIL MOUNTED CONVEYOR BELT

NAME: ZIKI RONALD

PROGRAM: MECHATRONICS ENGINEERING
RE NUMBER: C1213433A
SUPERVISOR: MR SIMANGO

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 DESIGN OF A SMART AIRBAG DEPLOYMENT SYSTEM FOR VEHICLES

Chapter 1: Results.
Results in this chapter were done against the system requirement and the objectives to see
if both were met by the system.

1.1: Mechanical

From the car crash simulation, the author found that at a speed of 200km/h the car a deceleration
of 325m/ s2 is experienced by the car and this was treated as the worst-case scenario as the
module will be also part of the car it will experience the same deceleration and the force due to
that which is calculated as follows:

Using Newton’s second law of motion;

f =ma

Mass of the module is taken from the solid works drawing and it was found to be 1275.85 grams

Therefore;

f =1.27585 ×325

¿ 414.65 N

Performing finite element analysis on the casing to make sure it will not break during the
collision

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 DESIGN OF A SMART AIRBAG DEPLOYMENT SYSTEM FOR VEHICLES

   

 VON: von Mises Stress 0 N/m^2 242530 N/m^2
Node: 2228 Node: 36644


Figure 1: Vonmises analysis on mechanical design

Minimum damages were witnessed after loading the casing with maximum possible force caused by the
deceleration of the vehicle from the maximum speed to zero during a crush

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 DESIGN OF A SMART AIRBAG DEPLOYMENT SYSTEM FOR VEHICLES

1.1.1: Thermal analysis





Figure 2: Thermal analysis

1.2: Electrical
The main requirement that the electric domain is supposed to meet is that it is to make sure the
module remains powered for six hours after the main power source have been lost, this is to
make sure the module remains powered even after the crush have occurred for it to complete the
airbag deployment and task and sending an accident alert message and also for the rescue team to
be able to use the mobile tracking system to track the actual position of the SIM card.

A Simulink model was used to experiment if the designed power supply was able to do as
described. Since the designed system is an uninterrupted power supply the model consists of two
batteries that is the main car battery acting as the main power supply and the system backup
battery. In this experiment the main power supply will cut at a given time and the backup battery
will get on load results will then be recorded.

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 DESIGN OF A SMART AIRBAG DEPLOYMENT SYSTEM FOR VEHICLES

Figure 3: Simulink model on system battery decay

1.2.1: Results

Figure 4: battery decay results

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 DESIGN OF A SMART AIRBAG DEPLOYMENT SYSTEM FOR VEHICLES

Above shows the results from the simulation from the state of charge graph it can be seen that it takes an
hour and a half for the battery to be fully charged and the discharging from full capacity took 6 hours to
the lowest voltage that can power the system in this case 40% of 12 volts which is 5 volts. This shows
that the designed power supply have met its objectives.

1.3: Electronics
Simulations were done in the electronic domain using proteus electronic simulation software and
the following results were found. These simulations were done on the integrated circuit to see if
the system was able to meet its intended objectives and requirements.Below is a screen shot of
the system simulation in running mode.

The electronic domain is the main domain in this project since the module is an electronic system
so for this there was need for more detail, so the results will be done against objectives set in the
first chapter of the project.

1.3.1: Level monitoring

As the system is powered, thebunker level sensors will immediately start sending signal from which the
microcontroller will extract the level of each bunker as shown below.

GPS signal

Figure 5: GPS output signal

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 DESIGN OF A SMART AIRBAG DEPLOYMENT SYSTEM FOR VEHICLES

1.3.2: Bunker filling

The author then tested the coal delivery system by sending a low bunker level signal to the
microcontroller to see if it will be able to meet the following requirements

1. move the mobile belt to the location of the bunker

2. Run the mobile belt
3. Run the supply belt 500ms after mobile belt reaches the location of the bunker

GPS signal 3 massages were send

Figure 6:3 LocationMassages Sent

For the delay measurement, an oscilloscope was used to measure the time difference between the
signal from the accelerometer and the deployment time

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 DESIGN OF A SMART AIRBAG DEPLOYMENT SYSTEM FOR VEHICLES

Figure 7: airbag deployment delay

A delay of 450ms was archived which is in the desired range.

During this simulation,the system quickly picked the bunker low level signal from the level

sensors and the system responded by moving the mobile belt to that bunker, trigering the mobile

belt followed by the main supply conveyor belt to re-fill the bunker.The system also displayed

the ongoing process on the LCD. With the perfect results above which were obtained from

prototype simulation of the project, it shows that the major challenge in industries of coal bunker

level monitoring and multi bunker re-filling process from one main supply conveyor belt can be

easly and effectively solved by this accurate fast and reliable morden technical way

By achieving this goal effectively ,accurately and in short period of time, this will save industries
by minimizing cost that maybe aquired by using long processes which needs more time and
labour

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 DESIGN OF A SMART AIRBAG DEPLOYMENT SYSTEM FOR VEHICLES

Chapter 2: Conclusion And Recommendations

2.1: Cost benefit analysis

2.1.1: COMPONENTS COST

The summation of all costs for each individual component which develop the system is shown
in the table below

2.1.2: TRAINING COS

Few qualified personel can install the system by following the manual installation guide. It also needs a
little operating training

2.1.3: COMMISIONING COST

They are costs that deal with the testing of the system and error debugging whilst the system is
being installed
Miscellaneous cost $ 150
External service $400
2.1.4: COMPONENT COSTING

COMPONENT COST
Arduino mega 1280 $ 60-00
Serial connection cable $10-00
GPS Module $40-00
GSM Module $20-00
relays $ 10-00
Display unit $5
Power supply $50-00
Capacitors $2-00
resistors $2-00
Total $199

Total cost = costs of components +training costs+ commissioning costs +general costs
+external costs
= $199 + $100 + $50
= $249.

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 DESIGN OF A SMART AIRBAG DEPLOYMENT SYSTEM FOR VEHICLES

2.2: Conclusion
From the first point, the main objective of this project was to design a microcontroller based

multi-bunker level monitoring and re-filling system . All these objectives were fulfilled since the

system manages to perform well ,effectively and in real time during simulation of the proteus

design.

During the simulation of the system design, Once there was a bunker with low level,the sensors

send signal to the microcontroller which respond by moving the mobile belt to that bunker,

triggering it,followed by trigerring the main supply conveyor belt.When the bunker is full, the

full level sensor sends signal to the microcontroller again which responds by switching off the

main supply belt followed by the mobile belt. This made level monitoring and bunker re-filling

more easier ,accurate, obtained with less labour and fast and this as a result reduces downtime

and saves company from loses. Moreso the goal have been achieved without design complexity

and also it was met at low cost.

The author was able to meet all the objectives of the research project

5.3: CHALLENGES
Time and resources did not permit for confirmation experiments

The other challenge faced by the author during research was that he had little knowledge on the
MATLAB simulation software and had to learn them before modeling the system

Since conveyor belt experiments experiments are expensive the author had to use simulation
tools in order to come up with the results.

2.3: Recommendations
The author recommends real world conveyor belt experiments in order to come up with accurate
results. On future works the author also recommends integration of coal outflow from each

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bunker so that the average time each bunker can take is calculated and saved in the system so
that in addition to level sensors, it can be also used as another monitoring variable.

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