DESIGN AND FABRICATION OF

MODIFIED FUEL LESS AIR ENGINE

CONTENTS

CONTENTS
CHAPTER NO TITLE
SYNOPSIS
LIST OF FIGURES
NOMENCLATURE
1 Introduction
2 Literature review
3 Description of equipments
3.1 Solenoid Valves
3.2 cam
3.3 Piston
3.4 Compressor
3.5 POT
4 Design and drawing
5 Working Principle
6 Merits and demerits
7 Application
8 List of material
9 Cost Estimation
10 Conclusion
Bibliography
Photography
 LIST OF FIGURES

LIST OF FIGURES

Figure
Number Title
1 Block Diagram
2 Overall Diagram
 NOMENCLATURE

NOMENCLATURE


A = Area of cylinder (m2)

D = Diameter of Piston (m)

F = Force exerted on the piston (N)

H = Height (m)

L = Length (m)

P = Pressure (N/M2)

V = Volume (m3)
 SYNOPSIS

SYNOPSIS
 The Air Driven Engine is an eco-friendly engine which operates with
compressed air. An Air Driven Engine uses the expansion of compressed air to
drive the pistons of an engine An Air Driven Engine is a pneumatic actuator that
creates useful work by expanding compressed air. There is no mixing of fuel
with air as there is no combustion.

An Air Driven Engine makes use of Compressed Air Technology for its
operation The Compressed Air Technology is quite simple. If we compress
normal air into a cylinder the air would hold some energy within it. This energy
can be utilized for useful purposes. When this compressed air expands, the
energy is released to do work. So this energy in compressed air can also be
utilized to displace a piston.
CHAPTER – 1

INTRODUCTION

CHAPTER – 1
INTRODUCTION
 At first glance the idea of running an engine on air seems to be too good
to be true. Actually, if we can make use of air as an aid for running an engine it
is a fantastic idea. As we all know, air is all around us, it never runs out, it is
non-polluting and it is free. An Air Driven Engine makes use of Compressed
Air Technology for its operation. Compressed Air Technology is now widely
preferred for research by different industries for developing different drives for
different purposes. The Compressed Air Technology is quite simple. If we
compress normal air into a cylinder the air would hold some energy within it.
This energy can be utilized for useful purposes. When this compressed air
expands, the energy is released to do work. So this energy in compressed air can
also be utilized to displace a piston. This is the basic working principle of the
Air Driven Engine. It uses the expansion of compressed air to drive the pistons
of the engine. So an Air Driven Engine is basically a pneumatic actuator that
creates useful work by expanding compressed air. This work provided by the air
is utilized to supply power to the crankshaft of the engine. In the case of an Air
Driven Engine, there is no combustion taking place within the engine. So it is
non-polluting and less dangerous. It requires lighter metal only since it does not
have to withstand elevated temperatures. As there is no combustion taking
place, there is no need for mixing fuel and air. Here compressed air is the fuel
and it is directly fed into the piston cylinder arrangement. It simply expands
inside the cylinder and does useful work on the piston. This work done on the
piston provides sufficient power to the crankshaft
 CHAPTER – 2

LITERATURE REVIEW

CHAPTER – 2

[Link] SURVEY`
 A heat engine is a machine, which converts heat energy into mechanical
energy. The combustion of fuel such as coal, petrol, diesel generates heat. This
heat is supplied to a working substance at high temperature. By the expansion of
this substance in suitable machines, heat energy is converted into useful work.
Heat engines can be further divided into

two types:

(i) External combustion and

(ii) (ii) Internal combustion.

CONSTRUCTIONAL FEATURES OF IC ENGINE:

The cross section of IC engine is shown in Fig. 1. A brief description of these

parts is given below.

Cylinder:

The cylinder of an IC engine constitutes the basic and supporting portion

of the engine power unit. Its major function is to provide space in which the
piston can operate to draw in the fuel mixture or air (depending upon spark
ignition or compression ignition), compress it, allow it to expand and thus
generate power. The cylinder is usually made of high-grade cast iron. In some
cases, to give greater strength and wear resistance with less weight, chromium,
nickel and molybdenum are added to the cast iron.

Piston:

The piston of an engine is the first part to begin movement and to

transmit power to the crankshaft as a result of the pressure and energy generated
by the combustion of the fuel. The piston is closed at one end and open on the
other end to permit direct attachment of the connecting rod and its free action.
The materials used for pistons are grey cast iron, cast steel and aluminium alloy.
However, the modern trend is to use only aluminium alloy pistons in the tractor
engine.

Piston Rings:

These are made of cast iron on account of their ability to retain bearing
qualities and elasticity indefinitely. The primary function of the piston rings is
to retain compression and at the same time reduce the cylinder wall and piston
wall contact area to a minimum, thus reducing friction losses and excessive
wear. The other important functions of piston rings are the control of the
lubricating oil, cylinder lubrication, and transmission of heat away from the
piston and from the cylinder walls. Piston rings are classed as compression rings
and oil rings depending on their function and location on the piston.
Compression rings are usually plain one-piece rings and are always placed in
the grooves nearest the piston head. Oil rings are grooved or slotted and are
located either in the lowest groove above the piston pin or in a groove near the
piston skirt. Their function is to control the distribution of the lubricating oil to
the cylinder and piston surface in order to prevent unnecessary or excessive oil
consumption ion.

Crankshaft:

This is connected to the piston through the connecting rod and converts
the linear motion of the piston into the rotational motion of the flywheel. The
journals of the crankshaft are supported on main bearings, housed in the
crankcase. Counter-weights and the flywheel bolted to the crankshaft help in the
smooth running of the engine.

Engine Bearings:
 The crankshaft and camshaft are supported on anti-friction bearings.
These bearings must be capable of with standing high speed, heavy load and
high temperatures. Normally, cadmium, silver or copper lead is coated on a
steel back to give the above characteristics. For single cylinder
vertical/horizontal engines, the present trend is to use ball bearings in place of
main bearings of the thin shell type.

.
 CHAPTER-3

DESCRIPTION OF EQUIPMENTS

CHAPTER-3

DESCRIPTION OF EQUIPMENTS
3.1 SOLENOID VALVE:

The directional valve is one of the important parts of a pneumatic system.

Commonly known as DCV; this valve is used to control the direction of air flow

in the pneumatic system. The directional valve does this by changing the

position of its internal movable parts.

This valve was selected for speedy operation and to reduce the manual

effort and also for the modification of the machine into automatic machine by

means of using a solenoid valve.

A solenoid is an electrical device that converts electrical energy into

straight line motion and force. These are also used to operate a mechanical

operation which in turn operates the valve mechanism. Solenoid is one is which

the plunger is pulled when the solenoid is energized.

PARTS OF A SOLENOID VALVE

1. Coil

The solenoid coil is made of copper wire. The layers of wire are separated

by insulating layer. The entire solenoid coil is covered with a varnish that is not

affected by solvents, moisture, cutting oil or often fluids. Coils are rated in

various voltages such as 115 volts AC,230volts AC,460volts Ac,575 Volts

AC.6Volts DC,12Volts DC,

24 Volts DC,115 Volts DC &230Volts [Link] are designed for such

Frequencies as 50Hz to 60Hz.

2. FRAME

The solenoid frame serves several purposes. Since it is made of laminated

sheets, it is magnetized when the current passes through the coil. the magnetized

coils attract the metal plunger to move. The frame has provisions for attaching

the mounting.

They are usually bolted or welded to the frame. The frame has provisions

for receivers, the plunger. The wear strips are mounted to the solenoid frame,

and are made of materials such as metal or impregnated less Fiber cloth.

3. SOLENOID PLUNGER

The solenoid plunger is the mover mechanism of the solenoid. The plunger

is made of steel laminations which are riveted together under high pressure, so

that there will be no movement of the lamination with respect to one another. At

the top of the plunger a pin hole is placed for making a connection to some

device. The solenoid plunger is moved by a magnetic force in one direction and

is usually returned by spring action.

Solenoid operated valves are usually provided with cover either the solenoid

or the entire valve. This protects the solenoid from dirt and other foreign matter,

and protects the actuator. In many applications it is necessary to use explosion

proof solenoids.

3.2.1. WORKING OF SOLENOID VALVE:

 The solenoid valve has 5 openings. These ensure easy exhausting of

5/[Link] spool of the 5/2 valve slide inside the main bore according to spool

position: the ports get connected and disconnected.

The working principle is as follows.

Position-1

When the spool is actuated towards outer direction port ‘P’ gets

Connected to ‘B’ and ‘S’ remains closed while ‘A’gets connected to ‘R’.

Position-2

When the spool is pushed in the inner direction port ‘P’ and ‘A’

Gets connected to each other and ‘B’ to ‘S’ while port ‘R’remains closed.

SOLINOID VALVE (OR) CUT OFF VALVE:

The control valve is used to control the flow direction is called cut off valve or

solenoid valve. This solenoid cutoff valve is controlled by the electronic control

unit.

In our project separate solenoid valve is used for flow direction of vice

cylinder. It is used to flow the air from compressor to the single acting cylinder.
3.2 CAM:

Cam arrangement

A cam is a rotating or sliding piece in a mechanical linkage used

especially in transforming rotary motion into linear motion or vice-versa. It is

often a part of a rotating wheel (e.g. an eccentric wheel) or shaft (e.g. a cylinder

with an irregular shape) that strikes a lever at one or more points on its circular

path. The cam can be a simple tooth, as is used to deliver pulses of power to a

steam hammer, for example, or an eccentric disc or other shape that produces a

smooth reciprocating (back and forth) motion in the follower, which is a lever

making contact with the cam. The cam can be seen as a device that rotates from

circular to reciprocating (or sometimes oscillating) motion. A common example

is the camshaft of an automobile, which takes the rotary motion of the engine

and translates it into the reciprocating motion necessary to operate the intake

and exhaust valves of the cylinders. Cams can also be viewed as information-

storing and transmitting devices. Examples are the cam-drums that direct the

notes of a musical box or the movements of a screw machine's various tools and

chucks. The information stored and transmitted by the cam.

Cam nomenclature:

Cam Profile

The contour of the working surface of the cam.

Tracer Point

The point at the knife edge of a follower, or the center of a roller, or the

center of a spherical face.

Pitch Curve
 The path of the tracer point.

Base Circle

The smallest circle drawn, tangential to the cam profile, with its center on

the axis of the camshaft. The size of the base circle determines the size of

the cam.

Prime Circle

The smallest circle drawn, tangential to the pitch curve, with its center on

the axis of the camshaft.

Pressure Angle

The angle between the normal to the pitch curve and the direction of

motion of the follower at the point of contact.

3.3 PISTON:

The piston of an engine is the first part to begin movement and to

transmit power to the crankshaft as a result of the pressure and energy generated
by the combustion of the fuel. The piston is closed at one end and open on the
other end to permit direct attachment of the connecting rod and its free action.
The materials used for pistons are grey cast iron, cast steel and aluminium alloy.
However, the modern trend is to use only aluminium alloy pistons in the tractor
engine.
3.4 COMPRESSOR

A gas compressor is a mechanical device that increases the

pressure of a gas by reducing its volume. Compressors are similar to pumps:

both increase the pressure on a fluid and both can transport the fluid through a

pipe. As gases are compressible, the compressor also reduces the volume of a

gas. Liquids are relatively incompressible, so the main action of a pump is to

transport liquids.

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 that of the air at intake conditions

namely at atmosphere pressure and normal ambient temperature.

Clean condition of the suction air is one of the factors, which decides the

life of a compressor. Warm and moist suction air will result increased

precipitation of condense from the compressed air.

Compressor may be classified in two general types.

1. Positive displacement compressor

2. Turbo compressor
Positive displacement compressors are most frequently employed for

Compressed air plant and have proved highly successful and supply air for

pneumatic control application.

The types of positive compressor

1. Reciprocating type compressor

2. Rotary type compressor

Turbo compressors are employed where large of air required at low

discharge pressures. They cannot attain pressure necessary for pneumatic

control application unless built in multistage designs and are seldom

encountered in pneumatic service.

RECIPROCATING COMPRESSORS:

Built for either stationary (or) portable service the reciprocating

compressor is by far the most common type. Reciprocating compressors lap be

had is sizes from the smallest capacities to deliver more than 500m3/[Link]

single stage compressor, the air pressure may be of 6 bar machines discharge of

pressure is up to [Link] pressure in the range of 250bars can be

obtained with high pressure reciprocating compressors that of three & four

stages. Single stage and 1200 stage models are particularly suitable
 For applications, with preference going to the two stage design as soon as

the discharge pressure exceeds 6 bars, because it in capable of matching the

performance of single stage machine at lower costs per driving powers in the

range.

The compressibility of the air was first investigated by Robot Boyle in

1962 and that found that the product of pressure and volumes of particular

quantity of gas.

The usual written as

PV =C (or) P1V1 =P2V2

In this equation the pressure is the absolute pressured which for free is

about 14.7Psi and is of courage capable of maintaining a column of mercury,

nearly 30 inches high in an ordinary barometer.

3.4 POT (POTENTIOMETER)

A potentiometer is a three-terminal resister with a sliding contact that

forms an adjustable voltage divider. If only two terminals are used (one side
and the wiper), it acts as a varible resistor or Rheostat. Potentiometer are
commonly used to control electrical devices such as a volume control of a ratio.
Potentiometers operated by a mechanism can be used as position tranducers, for
example in a joystick.

Potentiometer are rarely used to directly control significant power (more

than a watt). Instead they are used to adjust the level of analog signals
(e.g volume control on audio equipment), and as control inputs for
electronic circuits. For examble a light dimmer uses a potentiometer to
control the switching of a TRIAC and so indirectly control the brightness
of lamps.

Potentiometers are sometimes provided with one or more switches

mounted on the same shaft. For instance , when attached to a volume
control, the knob can also function as an on/off switch at the lowest
volume.

APPLICATION OF POTENTIOMETERS

Potentiometers are widely used as user controls, and may control a

very wide variety of equipment functions. The widespread use of
potentiometers in consumer electronics has declined in the 1990s, with
digital contols now more common. However they remain in many
applications, such as volume controls and as position sensors.
CHAPTER-4
DIAGRAM
CHAPTER-4
DIAGRAM
 CHAPTER-5
WORKING PRINCIPLE
 CHAPTER-5
WORKING PRINCIPLE

A compressed-air vehicle is powered by an air engine, using compressed

air, which is stored in a tank. Instead of mixing fuel with air and burning it in
the engine to drive pistons with hot expanding gases, compressed air vehicles
(CAV) use the expansion of compressed air to drive their pistons. One
manufacturer claims to have designed an engine that is 90 percent efficient.
Compressed air propulsion may also be incorporated in hybrid systems, e.g.,
battery electric propulsion and fuel tanks to recharge the batteries. This kind of
system is called hybrid-pneumatic electric propulsion. Additionally,
regenerative braking can also be used in conjunction with this system.
CHAPTER – 6
MERITS
 CHAPTER – 6
MERITS

MERITS

 Air, on its own, is non-flammable.

 High torque for minimum volume.
 The mechanical design of the engine is simple and robust.
 Low manufacture and maintenance costs as well as easy maintenance.
 Compressed-air tanks can be disposed of or recycled with less pollution
than batteries.
CHAPTER – 7

APPLICATIONS
 CHAPTER – 7

APPLICATIONS

APPLICATIONS
 Compressed air engines were used in trams and shunters, and eventually
found a successful niche in mining locomotives
 Transport category airplanes, such as commercial airliners, use
compressed air starters to start the main engines. The air is supplied by
the load compressor of the aircraft's auxiliary power unit, or by ground
equipment.
 There is currently some interest in developing air cars. Several engines
have been proposed for these
 CHAPTER – 8

LIST OF MATERIALS
 CHAPTER – 8

LIST OF MATERIALS

FACTORS DETERMINING THE CHOICE OF MATERIALS

The various factors which determine the choice of material are discussed
below.

1. PROPERTIES

The material selected must possess the necessary properties for the
proposed application. The various requirements to be satisfied can be weight,
surface finish, rigidity, ability to withstand environment attack from chemicals,
service life, reliability etc.

The following four types of principle properties of materials decisively

affect their selection

a. Physical
b. Mechanical
c. From manufacturing point of view
d. Chemical

The various physical properties concerned are melting point, thermal

conductivity, specific heat, coefficient of thermal expansion, specific gravity,
electrical conductivity, magnetic purposes etc.

The various Mechanical properties concerned are strength in tensile,

compressive shear, bending, torsional and bucking load, fatigue resistance,
elastic limit, endurance limit and modulus of elasticity, hardness, wear
resistance and sliding properties.
 The various properties concerned from the manufacturing point of view
are,

 Cast ability
 Weld ability
 Surface properties
 Shrinkage
 Deep drawing etc.

2. MANUFACTURING CASE

Sometimes the demand for lowest possible manufacturing cost or surface

qualities obtainable by the application of suitable coating substances may
demand the use of special materials.

3. QUALITY REQUIRED

This generally affects the manufacturing process and ultimately the

material. For example, it would never be desirable to go casting of a less
number of components which can be fabricated much more economically by
welding or forging the steel.

4. AVAILABILITY OF MATERIAL

Some materials may be scarce or in short supply, it then becomes

obligatory for the designer to use some other material which though may not be
a perfect substitute for the material designed. The delivery of materials and the
delivery date of product should also be kept in mind.

5. SPACE CONSIDERATION

Sometimes high strength materials have to be selected because the forces

involved are high and space limitations are there.
 CHAPTER – 9

COST ESTIMATION
 CHAPTER – 9

COST ESTIMATION

COST

As in any other problem, in selection of material the cost of material

plays an important part and should not be ignored.

Some times factors like scrap utilization, appearance and non-

maintenance of the designed part are involved in the selection of proper
materials.

1. LABOUR COST

Lathe, drilling, welding, power hacksaw, gas cutting cost.

2. OVERHEAD CHARGES

The overhead charges are arrived by “manufacturing cost”

Manufacturing Cost = Material Cost + Labour Cost

Overhead Charges = 20% of the manufacturing cost

3. TOTAL COST

Total cost = material Cost + Labour Cost + Overhead Charges

=

=
CHAPTER – 10

CONCLUSION
 CHAPTER – 10

CONCLUSION

Thus we have developed an “AIR ENGINE” which helps to know how to

achieve compressed air vehicle. The application of pneumatics produces smooth
operation. By using more techniques, they can be modified and developed
according to the applications.
BIBLIOGRAPHY
 BIBLIOGRAPHY

 utomobile Engg. - N.M Aggarwal [Link] & Sons.

 [2] "Advances in Automobile Engg.", [Link] Allied Publishers
Ltd.
 [3] "Theory and Performance of Electrical Machines", J.B. Gupta, S.K
Kataria & Sons.
 [4] "Principles of Electrical Engg & Electronics, V.K Mehta.
 [5] "Engineering and Electronics", [Link].

PHOTOGRAPHY