JSS Mahavidyapeetha

JSS SCIENCE AND TECHNOLOGY UNIVERSITY

JSS Technical Institutions’ Campus, Mysuru – 570006

“DESIGN AND FABRICATE OF PNEUMATIC BUMPER

SYSTEM FOR HMV”

Thesis submitted in partial fulfilment of curriculum prescribed for the

award of the degree of

BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING
by

POORVITH MP GANESH CS
(01JST22UME424)

(01JST22UME409)

PRAJWAL SUJAN M
(01JST22UME425)

(01JCE21ME044)

Under the Guidance of

Mrs. BHAVYA V
Assistant Professor,
Department of Mechanical Engineering, JSS STU, Mysuru.

DEPARTMENT OF Mechanical ENGINEERING

May, 2025
 JSS MAHAVIDYAPEETHA
JSS SCIENCE AND TECHNOLOGY UNIVERSITY
SRI JAYACHAMARAJENDRA COLLEGE OF ENGINEERING
 Constituent College of JSS Science and Technology University
 Approved by A.I.C.T.E
 Governed by the Grant-in-Aid Rules of Government of Karnataka
 Identified as lead institution for World Bank Assistance under TEQIP Scheme
DIAMOND JUBILEE YEAR: 1963 – 2023

CERTIFICATE

This is to certify that the work entitled “DESIGN AND FABRICATE OF

PNEUMATIC BUMPER SYSTEM FOR HMV” is a Bonafide work carried out by
POORVITH MP, GANESH CS, PRAJWAL and SUJAN M in Partial fulfillment for
the award of the Degree of BACHELOR OF ENGINEERING IN MECHANICAL
ENGINEERING in Sri Jayachamarajendra College of Engineering, JSS Science and
Technology University, Mysuru, during the year 2025. It is certified that all
corrections/suggestions indicated during CIE have been incorporated in the report.
The project report has been approved as it satisfies the academic requirements in
respect of project work prescribed for the Bachelor of Engineering degree.

Guide Head of the department

Mrs. BHAVYA V Dr. G MALLESH
Assistant Professor Dept. of Mechanical Engineering,
Dept. of Mechanical Engineering, SJCE, JSS STU, Mysuru.
SJCE, JSS STU, Mysuru.

Examiners: 1. ………………………

Place: Mysuru 2. ………………………

Date: 3. ………………………
 DECLARATION

We hereby declare that the project titled “DESIGN AND FABRICATE OF

PNEUMATIC BUMPER SYSTEM FOR HMV” has been carried out by our project
group under the guidance of Mrs. BHAVYA V, Professor and Head, Department of
Mechanical Engineering, JSS Science and Technology University, Mysuru, in partial
fulfillment of the requirements for the award of the Bachelor of Engineering degree
by JSS Science and Technology University, Mysuru, during the academic year
2024–2025.
We further declare that this dissertation has not been submitted to any other
university or institution for the award of any degree or diploma.

POORVITH MP GANESH CS
(01JST22UME424) (01JST22UME409)

PRAJWAL SUJAN M
(01JST22UME425) (01JCE21ME044)

Place: Mysuru
Date:
 ABSTRACT

Rear-end collisions involving Heavy Motor Vehicles (HMVs) often result in severe
damage, injuries, and fatalities due to the vehicle’s large size and heavy weight.
Traditional bumper systems lack the capability to proactively prevent such accidents.
This project focuses on the development of a Pneumatic Bumper System using
ultrasonic sensor designed to enhance road safety by minimizing collision impact.
The system integrates ultrasonic sensor for pneumatic technology to create an
adaptive bumper.

The continuously analyzes real-time data from ultrasonic sensors to detect potential
collision threats. When a risk is identified, the system triggers a pneumatic actuator
controlled by a Arduino UNO, which rapidly deploys the bumper to absorb impact
energy. This quick response reduces the severity of accidents, protects both the HMV
and the other vehicle involved, and can even prevent under-ride crashes.

The design process involved creating detailed 3D models using SolidWorks and
conducting Finite Element Analysis (FEA) with ANSYS Workbench to evaluate the
system’s structural performance under various impact scenarios. Force calculations
were performed based on different vehicle speeds to simulate real-world conditions.
Aluminum 6061 was selected for the bumper material due to its lightweight, high
strength, and excellent energy absorption properties.

Prototype testing demonstrated that the sensor based pneumatic bumper effectively
reduces collision impact, enhances vehicle safety, and aligns with modern
transportation safety standards. This innovative system shows great potential for
reducing road accidents and saving lives, making it a valuable addition to the safety
features of heavy vehicles.
 ACKNOWLEDGEMENT

The satisfaction that accompanies the successful completion of a task would

be incomplete without the mention of the people who are responsible for the
completion of the project. We wish to express our sincere gratitude to those
.
whose timely guidance has made us accomplish this project.

We extend our most profound gratitude, immense pleasure, and heartfelt

thanks to our esteemed guide Mrs. BHAVYA V, Assistance Professor,
Department of Mechanical Engineering, JSS S&T University, Mysore, whose
enlightening guidance and support have always helped us accomplish our task
on hand.

We are extremely grateful to Dr. G MALLESH , Head of the Department

of Mechanical Engineering, JSS Science and Technology University, Mysuru
for permitting us to utilize all the facilities of the department.

We sincerely thank our respected former Principal Dr. C. Nataraju, for

providing us an excellent academic atmosphere and encouragement in SJCE.

We are also thankful to all the teaching and non-teaching staff members of
our department for their kind cooperation and help.
 Certificate
Abstract
Acknowledgement
List of Tables
List of Figures
1
Chapter-1: Introduction
2
1.1 Motivation on selected project
3
1.2 Scope of chosen project
3
1.3 Need for sensor based pneumatic bumper
4
1.4 Application of sensor-based vehicle bumper
1.5 Pneumatic advantages over hydraulic cylinders for this system 5
1.6 Pneumatic actuation in truck rear side 6

Chapter-2: Background theory and literature review objective 7

2.1 Determining the types of vehicles in which this system can be 7
Implemented
2.2 Pneumatic actuation 9
2. 3 Types of bumpers used in rear side of vehicle 10
2.4 Material selection 11
2.5 Physical properties of aluminium6061 12
2.6 Material Description 12
2.7 Literature review 13

Table of Contents
Chapter-3: Objective 16
3.1Objectives of the Project 13
3.2 Methods and Methodology 17
3.3 Components used 20
3.4 Code of PCB 27
3.5 Calculation 28
Chapter- 4: Analysis of a Vehicle Bumper Using solid works 30
4.1 3D Modeling in solid works 30
Chapter-5 Project costing 38
Chapter-6: Cad model 2D & 3D 39
Chapter-7: Conclusions and Suggestions for Future Work Conclusion 42
 List of Table

7
Table 2.1: Dimensions of Hyundai Sonata Car
8
Table 2.2: Dimensions of Bharat Benz 1617R truck

Table 2.3: Physical Properties of Aluminum 6061 12

Table 6.1: Project cost 38
Table of Fig

Fig 1.1: Under ride of vehicle 2

Fig 2.1: Hyundai Sonata car side view 7
Fig 2.2: Ford Icon car body frame 7
Fig 2.3: Side view of Bharat Benz 1617R truck 8
Fig 2.4: Back side view of Bharat Benz 1617R truck 8
Fig 2.5: Deep Drop Bumper 10
Fig 2.6: Roll Pan Bumper 10
Fig 2.7: Step Bumper 11
Fig 3.1: Pneumatic Cylinder 20
Fig 3.2: Raspberry pi 4 Model B 21
Fig 3.3: Pneumatic Valve 22
Fig 3.4: Hoses 23
Fig 3.5: Bumper Frame 24
Fig 3.6: compressor 24
Fig 3.7: Ultrasonic sensor 25
Fig 3.8: Buzzer 25
Fig 3.9: LCD Display with I2C 25
Fig 4.1: Cad model of bumper 30
Fig 4.2: Drafting of bumper 31
Fig 4.3: Meshing 32
Fig 4.4: Total deformation of bumper 33
Fig 4.5: Directional deformation 33
Fig 4.6: Normal elastic strain 34
Fig 4.7: Welding process 35
Fig 4.8: Chassis 35
Fig 4.9: Working simulation of the Mode 36
Fig 4.10: Drafting of prototype 37
Fig 4.11: Final Assembly 37
Fig 6.1: Base of chassis 39
Fig 6.2: Top of chassis 40
Fig 6.3: CAD model of prototype 41
 CHAPTER 1
INTRODUCTION
Heavy-duty trucks are critical to transportation and logistics industries
worldwide, but their size and weight pose significant risks during accidents,
particularly rear-end collisions. Conventional safety mechanisms often fail to provide
adequate protection for vehicles and individuals involved in such scenarios. To
address this issue, a sensor-based pneumatic bumper system is proposed as one of the
intelligent solutions to enhance safety standards. This system integrates ultrasonic
sensor with pneumatic mechanisms to create a dynamic, adaptive bumper designed
specifically for the rear side of heavy-duty trucks. The primary objective is to
minimize collision impact through proactive and reactive measures, leveraging real-
time data and advanced control algorithms.
Rear underride crashes involving heavy motor vehicles (HMVs) are a
significant cause of fatalities and severe injuries on roads. These incidents occur when
smaller vehicles collide with the rear of HMVs, leading to intrusion into the passenger
compartment due to insufficient energy absorption mechanisms. Traditional rear
guards often fail to mitigate such impacts effectively, highlighting the need for
innovative solutions.
This project focuses on designing and developing a sensor based pneumatic
bumper system for HMVs to address the issue of rear underride crashes. The proposed
system uses advanced real time data to detect potential collision scenarios in real time
and deploys a pneumatic bumper to absorb impact energy, thereby reducing the
severity of accidents.
The integration of sensor ensures that the system can anticipate and respond to
risks dynamically, while the pneumatic mechanism provides robust energy absorption
and rapid deployment. This innovative approach aims to enhance road safety
standards and reduce fatalities associated with rear underride crashes.
The aim of this project is to develop an sensor-based pneumatic bumper
system for Heavy Motor Vehicles (HMV) that enhances collision safety by
dynamically adjusting the bumper’s position to absorb impact, reduce damage,
prevent under-ride crashes, and improve overall passenger and vehicle safety.
1.1. Motivation for selecting the topic
The development of a sensor-based pneumatic bumper system for heavy-duty
trucks is driven by the increasing need to address the high rate of fatalities and severe
damages caused by rear-end collisions, which are among the most common types of
road accidents involving large vehicles. Heavy-duty trucks often carry significant
momentum due to their weight, making sudden stops challenging and intensifying the
impact during collisions. Traditional safety systems lack the capability to proactively
anticipate and mitigate such incidents, creating a gap in vehicular safety measures.
This gap motivates the adoption of intelligent, adaptive technologies that leverage
sensor for predictive analysis and quick response.
The urgency is further heightened by the rapid growth in transportation and
logistics, which has led to an increase in the number of heavy-duty vehicles on roads,
resulting in greater risks of accidents. By combining real-time sensors, and pneumatic
systems, this technology offers a transformative solution to reduce accident severity
and protect not only the vehicle occupants but also other road users. It also aligns with
global initiatives to promote safer and smarter transport systems, contributing to the
long-term goal of achieving Vision Zero—a strategy aimed at eliminating all traffic-
related fatalities and severe injuries.

Fig1.1 Under ride of vehicle

Road accidents involving heavy vehicles result in substantial costs for repairs,
insurance claims, and operational downtime. An effective collision mitigation system
can significantly reduce these financial burdens, providing both immediate and long-
term benefits to fleet operators and stakeholders. With advancements in ultrasonic
sensor and mechanical systems becoming more accessible, there is a unique
opportunity to implement such innovations at scale, driving the motivation to create a
safer, smarter, and more sustainable transportation ecosystem.
1.2 Scope of the chosen project
The scope of an sensor-based pneumatic bumper system for the rear side of
heavy-duty trucks is vast, encompassing significant advancements in road safety,
technology integration, and industry standards. This system has the potential to
revolutionize the transportation and logistics sectors by minimizing the risks
associated with rear-end collisions. Its application extends to a wide range of heavy
vehicles, including freight trucks, buses, and emergency vehicles. By integrating real-
time sensing, sensor-powered collision prediction, and adaptive pneumatic
mechanisms, the system addresses safety concerns in diverse traffic conditions, from
congested urban areas to high-speed highways. Beyond enhancing safety, this
technology aligns with evolving regulatory requirements and industry standards for
commercial vehicle safety, offering economic benefits through reduced repair costs
and downtime. Moreover, its scalability and adaptability open doors for
implementation in other vehicle categories, fostering innovation in automotive safety
systems and setting a new benchmark for intelligent safety solutions.

1.3 Need for sensor based pneumatic bumper

The need for a sensor-based pneumatic bumper system arises from the growing
challenges and risks associated with heavy-duty trucks on roads, which include their
size, weight, and potential for causing severe damage in rear-end collisions.
Traditional safety systems often fall short in providing adequate protection, especially
in dynamic traffic conditions. Here are the key reasons that underscore the need for
such a system:

 High Incidence of Rear-End Collisions: Rear-end collisions are one of the

most common types of road accidents, often resulting in severe damage and
fatalities, especially when large vehicles like heavy-duty trucks are involved.
The massive size and momentum of these vehicles amplify the impact, making
it crucial to develop systems that minimize collision effects.
 Delayed Braking and Reaction Time: Due to their significant weight and
braking distance, heavy-duty trucks cannot stop as quickly as smaller vehicles.
This delay increases the risk of accidents, necessitating a proactive system that
can predict and respond to potential collisions in real time.
Integration with Emerging Technologies: As vehicles increasingly incorporate
advanced technologies like ADAS (Advanced Driver Assistance Systems) and
autonomous driving features, there is a growing need for complementary safety
systems. A sensor-powered pneumatic bumper integrates seamlessly with these
systems, enhancing overall vehicle safety.

1.5 Applications of sensor based vehicle bumper

Heavy-Duty Trucks and Logistics Vehicles

 Purpose: Protects large freight-carrying vehicles on highways and
urban roads.
 Benefit: Reduces rear-end collision impact, ensuring safety
for drivers and other road users while minimizing cargo
damage.

Public Transport Vehicles

 Purpose: Applied to buses and coaches to enhance

passenger and pedestrian safety.
 Benefit: Mitigates the risk of accidents in crowded
urban environments and reduces damage during low-speed
impacts.
Emergency Response Vehicles
 Purpose: Equips ambulances, fire trucks, and other emergency vehicles
that operate in high-speed or unpredictable traffic conditions.
 Benefit: Enhances operational safety, allowing these vehicles to respond
efficiently without risking severe rear-end impacts.

Autonomous and Semi-Autonomous Vehicles

 Purpose: Integrated with autonomous trucks or vehicles to
complement collision avoidance systems.
 Benefit: Provides an additional layer of safety by dynamically
responding to unforeseen rear-end collision scenarios.

Passenger Vehicles (Future Scope)

 Purpose: Adapted for cars and SUVs to provide intelligent
collision mitigation in smaller vehicles.
 Benefit: Expands the reach of smart safety systems to personal
vehicles, improving overall road safety.

1.6 Pneumatics advantages over hydraulic cylinders for this system

Pneumatics refers to systems or devices that are powered by

compressed air or gas. The term originates from the Greek word pneuma,
meaning wind. Pneumatics is a branch of engineering that uses the energy
stored in compressed air to perform mechanical work, such as moving,
lifting, or operating machinery.

Pneumatic cylinders offer several advantages over hydraulic

cylinders, making them ideal for specific applications. Pneumatics are
generally faster due to the lower density of air and have a lower initial cost
and maintenance requirements compared to hydraulics, which rely on oil and
more complex systems like pumps and reservoirs. Pneumatic systems are
lighter and more compact, making them suitable for weight-sensitive
applications, and they naturally provide overload protection, as compressed
air compresses further or escapes under excessive load, preventing damage.
1.7 Pneumatic actuation in trucks rear end

 Impact Absorption:
 Pneumatic actuators use compressed air to deploy
bumpers or cushioning mechanisms during a collision.

 They absorb and dissipate the energy from impacts,

reducing damage to the truck and other vehicles involved.

 Real-Time Deployment:
 Sensors monitor traffic conditions, and the system uses
real-time data to predict potential collisions.
 Pneumatic actuators quickly extend or adjust the bumper
when a collision is imminent, providing adaptive
protection.

 Enhanced Safety:
 By dynamically responding to varying collision forces,
pneumatic actuation minimizes the risk of injury to
occupants and damage to cargo or surrounding vehicles.
 It is especially effective in high-speed or heavily loaded truck
scenarios.4.

 Integration with sensor:

• Pneumatic actuation in trucks can be integrated with
sensor-based systems to enhance functionality.

• Ultrasonic sensor optimizes the timing, force, and

deployment angle of the pneumatic bumper, ensuring
maximum protection and energy efficiency.
[Link] Theory and Literature Review

2.1 Determining the types of vehicles in which this system can be

implemented
Workshops and garages were visited to evaluate the available space in Light
Motor Vehicles (LMVs), Small Commercial Vehicles (SCVs), and Heavy Motor
Vehicles (HMVs) for the implementation of an sensor-based pneumatic bumper system.
For Light Motor Vehicles (LMVs), we evaluated the space in the Hyundai Sonata,
Renault Duster, and Ford Ikon. For Small Commercial Vehicles (SCVs), the rear space
of the Tata Ace was examined. For Heavy Motor Vehicles (HMVs), the dimensions of
the Bharat Benz 1617R were analyzed to assess the feasibility of fitting the system at
the rear end.

Fig2.1: Hyundai Sonata car side view Fig2.2: Ford Icon car body frame

Table 2.1: Dimensions of Hyundai Sonata Car

Dimension Measurement

Overall Length 192.9 inches (4,900 mm)

Overall Width 73.2 inches (1,860 mm)

Minimum Ground Clearance 5.3 inches (135 mm)

Seating Capacity 5 passengers

 Insufficient ground clearance, increases the impact on passengers during a
collision, affects the aesthetic appearance of the car, provides limited space for
installing the pneumatic cylinder and necessitates significant modifications to the
overall structure of the vehicle.

For SCVs the implementation of a sensor-based pneumatic bumper system in

the Tata Ace was deemed unfeasible due to several limitations. The vehicle's compact
design and limited rear-view space make it challenging to accommodate the pneumatic
cylinder and associated components without significant modifications. Additionally, the
Tata Ace is designed for economical and lightweight operation, and adding a pneumatic
system would increase both weight and cost, potentially affecting its performance and
affordability. The low ground clearance further restricts the installation of the system,
as it could interfere with the vehicle's safety. These factors collectively make the
integration of an sensor-based pneumatic bumper impractical for the Tata Ace.

Fig 2.3: Side view of Bharat Benz Fig 2.4: Back side view of Bharat Benz

Table 2.2 : Dimensions of Bharat Benz 1617R truck

Specification Details

Overall Length 8,600 mm

Overall Width 2,440 mm

Ground Clearance 270 mm

implementing an sensor-based pneumatic bumper system in the Bharat Benz 1617R is
not only feasible but also highly advantageous. The vehicle's dimensions are
sufficient, including its spacious rear-end design and high ground clearance, provide
sufficient room for installing the pneumatic cylinder and related components without
requiring significant structural alterations. This system enhances safety by proactively
reducing collision impact, especially in high-risk scenarios. One of its key benefits is
preventing under-ride crashes for smaller vehicles by dynamically adjusting the
bumper position, thereby protecting the opposite vehicle and its occupants. It
minimizes the force of impact on the opposite vehicle, reducing damage and injuries.
The system also contributes to passenger safety by triggering the airbag system of the
opposite vehicle during a collision, providing an added layer of protection. This
integration significantly improves overall road safety while aligning with modern
safety standards, making it an invaluable addition to the Bharat Benz 1617R.

2.5 Pneumatic Actuation

 Pneumatic systems operate on compressed air to generate mechanical

movement. The key components include compressors, cylinders, valves, and
actuators.
 Pneumatic actuators can rapidly extend or retract, making them ideal for
dynamic applications like bumpers that need to deploy in real-time based on
collision risk.

 The compression and expansion of air in cylinders provide quick and smooth
motion, ideal for absorbing shock or impact energy, particularly in high-force
collisions.
Impact Dynamics and Collision Mitigation
 Collision dynamics theory focuses on understanding how forces and energy
transfer during an impact. For example, the force of impact in rear-end
collisions is influenced by the mass, speed, and stopping distance of
vehicles involved.
 The pneumatic bumper works by absorbing kinetic energy and dissipating it
through the controlled compression of air, reducing the impact force
transmitted to the truck and other vehicles.
 The timing and force of the bumper’s deployment are crucial for
minimizing damage. Early activation of the pneumatic system can reduce
the severity of the collision by extending the bumper at the correct angle
and speed.

2.7 Types of Bumpers used in rear side of vehicle

 Deep Drop Bumper (also known as a Cowboy Bumper)

This type of bumper is typically found on older trucks and is usually chrome
plated. Deep drop bumpers have a heavy-duty towing capacity and a lower ball
height than a step bumper. The drop from the bottom of the frame is usually 10 or
12 inches.

Fig2.6 Deep Drop Bumper

 Roll Pan Bumper

Roll pan bumpers are typically found on custom compact trucks. The
trailer hitches available will sit in the middle, behind the bumper.

Fig2.7 Roll Pan Bumper

  Step Bumper

This type of bumper is typically found on trucks, vans and SUVs. The small cutout
in the center looks like a step. This bumper also has holes for hitch balls and can be
used to tow lightweight trailers.

Fig2.8 Step Bumper

2.8 Material selection and its advantage

Material used: ALUMINIUM 6061
Using aluminum 6061 in a pneumatic bumper system offers several advantages,
it an ideal choice for such applications. Aluminum 6061 is lightweight yet highly
durable, which helps reduce the overall weight of the vehicle while maintaining the
structural integrity required for impact absorption. Its excellent corrosion resistance
ensures longevity and reliability, even in harsh environmental conditions. The
material's high strength-to-weight ratio and good energy absorption properties
allow it to effectively distribute and dissipate impact forces during a collision. This
not only minimizes damage to the vehicle equipped with the bumper but also
significantly reduces the impact transmitted to the opposite vehicle. By cushioning
the force and preventing abrupt deceleration, the aluminum 6061-based pneumatic
bumper helps protect the occupants of the opposite vehicle from severe injuries. Its
ability to deform and absorb energy efficiently also reduces the likelihood of
structural damage to the other vehicle, enhancing safety for all parties involved in
the event of a crash.
2.9 Physical Properties of Aluminum 6061

In this project work, for the development of frame structure Aluminum 6061
alloy was chosen. The properties of Aluminum 6061 is shown in table 2.4.

TABLE 2.3: Physical Properties of Aluminum 6061

Properties Units
Density 2.70 g/cm³
Ultimate Tensile Strength 310 MPa
Elongation at Break 12–17%
Hardness (Brinell) 95

Corrosion Resistance Excellent

2.10 Material Description

 Type: Aluminum 6061 is a versatile, heat-treatable aluminum alloy known for

its excellent strength-to-weight ratio.

 Composition: Composed mainly of aluminum, with magnesium (0.8–1.2%)

and silicon (0.4–0.8%) as primary alloying elements.

 Strength: Offers moderate to high strength, with a yield strength of

approximately 275 MPa in the T6 temper.

 Corrosion Resistance: Exhibits excellent resistance to corrosion in

most environments, making it ideal for outdoor applications.

 Thermal Conductivity: Provides good thermal conductivity, aiding in

heat dissipation for high-performance applications.
2.11 Literature review

1. Automatic Pneumatic Bumper and Braking System by Chawla et al. (2018)

Chawla et al. (2018) proposed an electronically intelligent braking system designed
to automatically detect obstacles ahead of a vehicle and apply brakes to avoid collisions. In
the event of an unavoidable collision, the system deploys a retractable pneumatic bumper to
absorb impact, thereby minimizing vehicle damage. The use of pneumatic technology is
emphasized for its simplicity and ease of implementation.

2. Smart Vehicle with Automatic Pneumatic Bumper System and Video

Surveillance
Kale and Gorale (2019) introduced a comprehensive safety system designed to
enhance vehicular safety by integrating an automatic pneumatic bumper mechanism with
video surveillance and distraction control features. The system employs ultrasonic sensors to
detect obstacles within a 50 cm range. Upon detection, a solenoid valve activates a double-
acting pneumatic cylinder, deploying a bumper that extends forward to absorb potential
collision impacts. Simultaneously, a Pi-Camera records a 5-second video, which is stored
locally. In the event of an accident, indicated by the activation of a mechanical switch, the
recorded video is automatically sent via email to predetermined contacts, such as hospitals or
relatives, using the SMTP protocol. Additionally, the system addresses driver distractions by
monitoring incoming or outgoing calls. When such calls are detected, the music system is
automatically turned off to minimize driver distraction, resuming normal operation once the
call ends. This integrated approach aims to reduce accident severity, provide immediate post-
accident information, and enhance overall driving safety.
[Link] Attenuator Design for Formula SAE Racing Cars
Belingardi and Obradović (2010) conducted a comprehensive study on the
design and simulation of an impact attenuator for a Formula SAE racing car, aiming
to enhance driver safety during frontal collisions. Their research emphasized the
importance of achieving a progressive force evolution to effectively absorb kinetic
energy and minimize peak deceleration
4. Impact Analysis of Automobile Bumpers with Rectangular Stiffeners
Babu and Rajesh (2020) conducted a study on the impact analysis of
automobile bumpers to enhance safety during collisions. The research focused on
designing a new bumper system incorporating rectangular stiffeners to effectively
absorb impact forces.
5. Accident Prevention System Using an Automatic Pneumatic Bumper
Sayed et al. (2017) developed an accident prevention system that integrates infrared
(IR) sensors with a pneumatic bumper mechanism to enhance vehicular safety. The system
utilizes IR sensors to detect obstacles in the vehicle's path. Upon detection, a control unit
activates a solenoid valve, allowing compressed air to flow into a double-acting pneumatic
cylinder. This action deploys a bumper that extends forward to absorb potential collision
impacts, thereby reducing the severity of accidents. The system is designed to provide pre-
crash safety by improving braking response time and maintaining safe distances between
vehicles. Experimental results demonstrated the system's effectiveness in minimizing vehicle
damage and passenger injuries during collisions. The study concludes that the automatic
pneumatic bumper system offers a viable solution for enhancing road safety by mitigating the
impact of frontal collisions.
6. Automatic Pneumatic Bumper System with Intelligent Braking Mechanism
Datir et al. (2023) proposed an advanced vehicle safety system that integrates an
automatic pneumatic bumper with an intelligent braking mechanism. The system is designed
to detect obstacles and automatically apply brakes while deploying a pneumatic bumper to
absorb collision impacts, thereby enhancing overall vehicle safety. The study reports
improvements in braking response time, extended crash distance, and reduced damage during
collisions. Additionally, the design aims to minimize passenger injuries and lessen reliance on
internal safety features like airbags. The authors suggest future enhancements, including the
replacement of infrared (IR) sensors with ultrasonic sensors, incorporation of eye-blink
detection for driver alertness, and adaptation of the bumper to function as an external airbag
for added safety.
7. Numerical Analytical Model for Low-Speed Bumper-to-Bumper Vehicle
Crashes
Scott et al. (2010) developed a numerical analytical model aimed at simulating
collinear low-speed bumper-to-bumper vehicle crashes. This model treats the car body
as a rigid structure and the bumper as a deformable structure attached to the vehicle.
The model utilizes Newton's laws to simulate the dynamics of such crashes and
estimate crash severity. The study demonstrated the model's ability to accurately
simulate crash tests by applying Newton's laws. The model could replicate crash
dynamics using measured or theoretical bumper deformation data, allowing
parametric studies on how variables like restitution and bumper stiffness influence
crash dynamics. It also provided a method to estimate the upper limit of crash severity
in real-world incidents
8. Simulation of Car Collision with an Impact Block
Kostek and Aleksandrowicz (2017) investigated the sensitivity of post-impact
vehicle movements to contact parameters using the V-SIM simulation software. Their
study focused on simulating a low-speed, collinear collision of a Fiat Cinquecento
with an impact block, comparing the simulation results with experimental data from
the Allgemeiner Deutscher Automobile-Club (ADAC) crash test. The initial
simulations using default parameters resulted in significant deviations from the
experimental outcomes. To improve the accuracy of the simulation, the authors
identified and adjusted several key contact parameters
3.0 OBJECTIVES

3.1 Objectives
 Objective 1: Enhance Safety During Low-Speed Collisions on
pneumatic bumper system.
 Objective 2: To Develop a Responsive Pneumatic Actuation System
to pneumatic bumper system for HMV.
 Objective 3 : To carry out the detailed design of the selected
concept of pneumatic bumper system for HMV.
 Objective 4: To fabricate, testing and demonstration of
pneumatic bumper system for HMV.
3.2. Methods and Methodology

Objective 01
Statement of Objective:
To review literature on pneumatic systems, materials used for vehicle bumpers, and
accident safety.
Methods / Methodology:
 1.1 Analyse existing pneumatic bumper systems, materials used for
bumpers, and accident safety systems.
 1.2 Gather and review literature on pneumatic systems, bumper materials,
and accident safety to establish a foundational understanding.
 1.3 Identify limitations in current designs to improve upon.
Resources:
 Journal papers
 Websites
 Books

Objective 02
Statement of Objective:
To arrive at the design specifications and calculations of an automatic air-powered
pneumatic vehicle bumper.
Methods / Methodology:
 2.1 Define specifications based on force absorption requirements, ideal
pneumatic pressure, and material strength.
 2.2 Perform analytical calculations for impact forces and energy absorption.
Resources:
 Journals
 Books
 Field visits
03. Statement of Objective
To develop various concepts of Sensor-Based Pneumatic Bumper System for
Heavy Motor Vehicles (HMVs) based on feasibility, cost, and durability.
Methods / Methodology
 3.1 Consider factors such as ease of pneumatic activation, system size, and
response time.
 3.2 Develop multiple design concepts through sketching and utilize concept
evaluation techniques to assess each design based on:
o Cost
o Durability
o Feasibility of implementation
 3.3 Select the most suitable concept based on the evaluation outcomes.
Resources
 Academic Journals
 Brainstorming Sessions
 Blender (for conceptual modelling)

04. Statement of Objective

To carry out detailed designing of the finalized concept for the sensor-based
Pneumatic Bumper System for HMVs and develop the geometrical model.
Methods / Methodology
 4.1 Use CAD software to create detailed 3D designs and assemblies of the
bumper system.
 4.2 Perform Finite Element Analysis (FEA) to simulate various impact
scenarios and refine the model based on analysis results.
Resources
 Laboratory Facilities
 Fusion 360 (for CAD modelling)
 Ansys (for FEA simulations)
05. Statement of Objective
To develop the prototype of sensor-based Pneumatic Vehicle Bumper and
demonstrate its working.
Methods / Methodology
 5.1 Fabricate the prototype using selected materials and pneumatic
components.
 5.2 Compare the prototype's performance results with theoretical predictions to
evaluate the design’s effectiveness.
Resources
 University Facilities
3.3 Components Used

 Pneumatic Cylinder

Pneumatic cylinders convert the potential energy of compressed air into

mechanical energy of applied force or the kinetic energy of motion. Within the
cylinder, two chambers are maintained at different air pressures. A piston,
sometimes called a rod, attached to the dividing wall is set in motion as the volume
of the Chambers changes in response to the relative pressure of the two chambers.
At least one of the chambers is connected to a port that allows for the flow of air in
and out of the cylinder.
Pneumatic actuators can extend and retract rapidly, making them ideal for
applications like bumpers where split-second deployment is crucial.
Pneumatic systems are simpler to repair and maintain compared to hydraulic
systems, as they do not require fluids like oil that can cause leaks and
contamination.

Fig 3.1 Pneumatic Cylinder

Table 3.1 Description of Pneumatic Cylinder

Brand TECHNO

Model Name/Number 16X50

Material Aluminum
Pressure 1.5-7 Bar
Key Components of Pneumatic Cylinder
1. Cylinder Tube: The outer casing that contains the air and houses the piston.
2. Piston: Moves inside the cylinder tube when compressed air is applied.
3. Rod: Connected to the piston, it extends outside the cylinder to transfer
motion.
4. End Caps: Seal the cylinder at both ends and often contain ports
for air entry and exit.
5. Seals: Prevent air leaks and ensure smooth operation.
6. Ports: Openings for air to enter and exit the cylinder.

Advantages
 Simple and cost-effective.
 High speed and force capabilities.
 Low maintenance compared to hydraulic systems.

Arduino UNO Model 3

Fig 3.2: Arduino UNO Model 3

 Arduino Uno is a microcontroller board. It’s built around the ATmega328P
microcontroller and is widely used for electronics projects, automation, and
prototyping.a microcontroller is designed to execute specific tasks, like controlling
motors, reading sensors, or managing LEDs. Arduino Uno runs simple programs called
"sketches" that control connected hardware components. The Arduino Uno Model 3,
also known as Arduino Uno Rev3, is one of the most popular microcontroller boards in
the Arduino family. It is based on the ATmega328P microcontroller and is widely used
for electronics projects, automation, and prototyping.

Key Features:

 Microcontroller: ATmega328P

 Digital I/O Pins: 14 (6 can be used as PWM outputs)

 Analog Input Pins: 6

 Clock Speed: 16 MHz

 Power Supply: 5V (via USB or external adapter)

 Connectivity: USB connection, power jack, ICSP header

 Memory: 32KB Flash, 2KB SRAM, 1KB EEPROM

 Replaceable Chip: The ATmega328P can be swapped if needed.

Pneumatic Valve

Pneumatic valves play an important role in a pneumatic system. They

determine how much air passes through and in which direction. This means that they
can be used as control valves, but also as safety valves that shut off the air supply in
dangerous situations or that depressurize the system.

Fig 3.3 Pneumatic Valve

 pneumatic push-to-connect fittings, commonly used in pneumatic systems to
join or extend air tubing. These fittings are designed for quick and secure
connections, where the tubing is inserted into the fitting and held firmly in place by
an internal gripping mechanism. The blue ends indicate the push-to-release
mechanism, allowing easy disconnection without tools. Made of durable materials
like plastic or composite with metal reinforcement, they are lightweight and
corrosion-resistant. These connectors are ideal for use in applications like air
compressors, automation systems, and pneumatic circuits, ensuring leak-free
operation and efficient air flow.

Hoses

Fig.3.4 : Hoses

Pneumatic air hose, a vital component in pneumatic systems used to transport

compressed air from a source, such as an air compressor, to various tools or
equipment. This flexible hose is typically constructed from durable materials
like rubber, polyurethane, or PVC, ensuring resistance to wear, kinking, and
environmental factors. The hose features metal fittings or couplers on both ends,
enabling secure connections to pneumatic tools and air supply systems. Its bright blue
color improves visibility in work environments, reducing the risk of tripping hazards.
Pneumatic air hoses are widely used in industrial, automotive, and construction
applications, providing reliable and efficient airflow for powering tools like drills,
nail guns, and spray systems.
 Bumper Frame

Bumpers are meant to protect motor vehicles from physical harm in the case
of a collision. A bumper is a structural component typically installed at the front and
rear ends of vehicles, designed to absorb and reduce the impact during collisions,
thereby protecting the vehicle's occupants and critical components. Modern bumpers
are engineered to combine functionality and aesthetics, often integrating shock-
absorbing materials like foam, rubber, or energy-absorbing plastic within a rigid
frame made of steel, aluminum, or composite materials.

3.5: Bumper Frame

Some advanced designs include pneumatic bumpers, which deploy or retract

automatically using compressed air to enhance collision protection. Bumpers are not
only essential for minimizing damage during low-speed impacts but also play a
critical role in pedestrian safety and vehicle aerodynamics.

Compressor
For a pneumatic bumper project, a compressor plays a vital role in
providing the compressed air required to power the pneumatic system. The
compressor is responsible for generating and maintaining sufficient air pressure to
operate the pneumatic cylinder, which extends or retracts the bumper to absorb or
prevent collision impact.

Fig 3.6 compressor

Ultrasonic sensor

Fig 3.8 Ultrasonic sensor

The ultrasonic sensor (or transducer) works on the same principles

as a radar system. An ultrasonic sensor can convert electrical energy into
acoustic waves and vice [Link] output of the ultrasonic sensor is a high
pulse with the same duration as the time difference between transmitted
ultrasonic bursts and the received echo signal.
Buzzer

An audio signaling device like a beeper or buzzer may be

electromechanical or piezoelectric. The main function of this is to convert the signal
from audio to sound.

Fig 3.9: Buzzer

LCD Display with I2C

Fig 3.12 : LCD Display with I2C

 The integration of an I2C LCD display with a Arduino UNO in a sensor-
based pneumatic bumper system provides a robust and efficient means of
displaying real-time data and system updates. The LCD can display critical
information such as obstacle detection warnings, pneumatic system status, and
sensor decision-making feedback, enhancing user awareness and safety.
Additionally, the adjustable backlight and contrast make the display easy to read in
various lighting conditions, which is crucial in automotive environments. This
seamless integration simplifies troubleshooting and monitoring, making the system
more user-friendly andFig
reliable.
3.10: Voltage regulator 7805
ATMEGA328

Fig 3.11: ATMEGA328

The Atmel ATmega328P is a 32K 8-bit microcontroller based on

the AVR architecture. Many instructions are executed in a single clock
cycle providing a throughput of almost 20 MIPS at 20MHz. The
ATMEGA328-PU comes in an PDIP 28 pin package and is suitable for
use on our 28 pin AVR Development Board.
3.4. Code for PCB
#include <Servo.h>
#define TRIG_PIN D5
#define ECHO_PIN D6
#define SERVO_PIN D7
Servo myServo;
void setup() {
[Link](9600);
pinMode(TRIG_PIN, OUTPUT);
pinMode(ECHO_PIN, INPUT);
[Link](SERVO_PIN);
[Link](0); // initial position
}
void loop() {
long duration, distance;
// Send ultrasonic pulse
digitalWrite(TRIG_PIN, LOW);
delayMicroseconds(2);
digitalWrite(TRIG_PIN, HIGH);
delayMicroseconds(10);
digitalWrite(TRIG_PIN, LOW);
// Measure pulse duration
duration = pulseIn(ECHO_PIN, HIGH);
distance = duration * 0.034 / 2; // convert to cm
[Link]("Distance: ");
[Link](distance);
// Rotate if distance <= 10 cm
if (distance <= 10) {
[Link](180);
} else {
[Link](0);
}
 3.5. calculations

For force calculation

 Mass of car = 925 kg

 Mass of four passengers = 300 kg, 75 kg

 Total mass of vehicle in motion

 M = mass pf car + mass of passengers

925 + 300 = 1225 kg
According to Newton’s second law of motion, the net force on a body is equal to
the product of the body’s mass and its acceleration
 F=mxa

 F = net force in N

 M = mass in kg

 a = acceleration in
m/s² a = (V – W)/t
 V = final velocity (m/s)

 W = initial velocity (m/s)

 t = time (S)

Assumptions
[Link] velocity = 0 m/s

[Link] = 1S

 Case 1

For Speed = 20km/h

V = 20 kmph
1 km/h = 1000/3600 m/s = 5/18 m/s

= 20km/h x 5/18 m/s per km/h

V = 100/18 m/s = 5.555 m/s

  a = (V – U)/t

a = (5.555-0)/1 = 5.555m/s²

F=mxa

=1225 x 5.555

F = 6804.87N
 CASE 2

For speed = 40 km/h

Similarly,

F = 13610.975 N
 CASE 3

For speed = 60 km/h

F = 20415.85 N
 CASE 4

For V = 80 km/h

F = 27222.222 N
 CASE 5

For V = 100 km/h

F = 34027.777 N
4.1 3D Modeling in SolidWorks Steps:

Conceptual Design: The bumper geometry was conceptualized

based on practical dimensions and functional requirements.

Dimensions and Features: The dimensions and key features, such

as curvature and mounting points, were specified.

SolidWorks Procedure:

 A new part file was created in SolidWorks.

 Sketching tools such as lines, splines, and arcs were used to define the
bumper’s 2D geometry.

 3D features like extrusion and fillets were applied to create the final
solid model.
 The model was saved in a compatible format (e.g., STEP or IGES) for
import into ANSYS.

Fig 4.1: Cad model of bumper

 Fig 4.2: Drafting of bumper

Importing Model into ANSYS Workbench

Steps:

ANSYS Workbench was opened, and the “Static Structural” module was
added to the project schematic.
The 3D model was imported by selecting the file exported from
SolidWorks. The geometry was checked and verified to ensure
compatibility.
Meshing
Steps:
The “Model” tab was opened to access the mechanical
environment. Meshing was performed:
o An appropriate element size was defined.
o The mesh was refined in areas prone to high stress concentrations.
The mesh quality was verified using parameters such as element aspect
ratio and skewness.
Material Properties
Steps:
1. Material properties, including Young’s modulus, Poisson’s ratio, and
density, were defined.
2. The bumper model was assigned the material properties.
Boundary Conditions and Loading
Steps:
1. Boundary conditions were applied to fix the mounting points or areas
where the bumper was attached to the vehicle.
2. Loading was applied:

o The type of load (e.g., distributed force or impact) was defined.

o The magnitude and direction of the applied load were specified.

Solving the Model
Steps:
The solver was configured to compute the results.

The analysis was run, and the convergence of the solution was monitored.

Fig 4.3: Meshing

 o The component was meshed using a triangular/tetrahedral finite element
mesh

o The mesh density appears to be uniform, ensuring

accurate stress and deformation distribution.

Fig 4.4: Total deformation of bumper

Total Deformation

 The maximum total deformation recorded is 1.4905 mm.

 The deformation is highest in the middle of the component,

confirming a bending effect due to applied loads or constraints.
 The minimum deformation is 0 mm, indicating the fixed support regions.

 The deformation pattern aligns with expected structural

behavior under applied loading conditions.

Fig 4.5: Directional deformation

 Fig 4.6: Normal elastic strain

Observations:

Directional Deformation (Z-Axis)

 The simulation analyzed directional deformation along the Z-axis.

 The maximum deformation observed is 0.21993 mm (marked in red).
 The minimum deformation observed is -0.21895 mm (marked in blue).
 The deformation distribution suggests bending in the Z-direction,
with higher displacement near the free end.

Normal Elastic Strain (Z-Axis)

 The maximum normal strain in the Z-axis is 0.00082865 mm/mm.

 The minimum normal strain in the Z-axis is -0.00070957 mm/mm.
 The strain is concentrated near the central region, which might
indicate potential stress concentration in that area.
 The strain values are relatively low, suggesting that the material is
within its elastic limit.

Structural Insights

 The maximum deformation and strain values are within acceptable

limits, meaning the structure is safe under the given loading
conditions.
 The bending effect suggests that the load application is asymmetric,
leading to non-uniform stress distribution.
The regions near constraints show minimal deformation,
which validates proper boundary conditions in the simulation.
 Fig 5.7: Welding process
The fig 4.64 shows the drilling operation using a handheld power
drill to create holes in a metal frame assembly. This step is essential for
fastening components together with screws or bolts, ensuring structural
integrity and ease of assembly. The workspace is well- organized, with
lockers and workbenches, reflecting a structured workshop environment.
The fig 4.63 indicates the welding process, where a worker is seen joining
metal components using an arc welding machine.

Fig 5.8: Chassis

 Fig 5.9: Working simulation of the Model
To better visualize and demonstrate the working of this system, Blender
software has been used to create a detailed simulation. This simulation
showcases how the sensor-based detection mechanism interacts with the
pneumatic bumper in real-world scenarios, allowing for a clear understanding of
its functionality before physical implementation. The entire setup is controlled
via a Arduino UNO model 3, which processes data from ultrasonic sensors
models to make quick and efficient decisions. By combining sensor-based
perception with a responsive pneumatic mechanism, this concept not only
enhances vehicle safety but also reduces accident severity for all parties
involved, making it a crucial advancement in modern vehicular safety
technology. The Ultrasonic sensor-based pneumatic bumper system for Heavy
Motor Vehicles (HMVs) was successfully designed and tested, demonstrating
significant improvements in collision safety. Upon detecting an imminent
collision, the sensor-driven control mechanism triggered the pneumatic bumper,
which deployed rapidly to absorb impact forces, reducing damage to both the
HMV and the opposite vehicle. The integration of Arduino UNO model 3
ensured seamless processing of sensor data, enabling quick decision-making.
Fig 5.10: Drafting of prototype

Fig 5.11: Assembled Model

 CHAPTER- 6
Project costing

The table shows the bill of material and estimated cost to make a
Ultrasonic sensor based pneumatic bumper for HMV.

Table 6.1: Project cost

Pneumatic Actuator Rs 1800

Pneumatic Pipes Rs 250

Pneumatic Fittings Rs 310

5/3 Pneumatic Value Rs 1100

Bumper Frame Rs 3500

Arduino UNO Model 3 Rs 1400

Wareing’s Rs 200

Solenoid Motor Rs 200

Supporting Rods, nut &bolt Rs 200

LCD Display with I2C Rs 350

Ultrasonic sensor Rs 300

Compressor Rs 2500

Cable wires Rs 300

Bread board Rs 100

Buzzer Rs 150

Total Rs 12,660
 CHAPTER- 7

CAD model 2D & 3D

Fig 7.1: Base of chassis

 Fig 7.2: Top of chassis

Fig 7.3: CAD model of prototype

 CHAPTER- 8
Conclusions and Suggestions for Future Work

The development of a sensor-based pneumatic bumper system for Heavy

Motor Vehicles (HMVs) represents a significant advancement in vehicular safety
technology. By integrating sensor-driven object detection with a responsive
pneumatic mechanism, the system proactively reduces the impact of collisions,
minimizing damage to both the HMV and the opposite vehicle. The use of
ultrasonic sensor for real-time obstacle recognition, coupled with ultrasonic
sensors for distance measurement, ensures high precision in detecting potential
hazards. The implementation of ultrasonic sensor for system control enables
efficient decision-making and rapid activation of the bumper.

The use of Blender software to simulate the working of the system has
provided valuable insights into its real-world application and effectiveness. This
approach not only enhances road safety but also reduces repair costs and the
severity of accidents. By combining automation, and pneumatic technology, this
project demonstrates a forward-thinking solution to modern transportation
challenges. Future improvements could focus on optimizing response time,
integrating additional safety features, and expanding its application to other types
of vehicles. Ultimately, this powered bumper system has the potential to
revolutionize vehicular safety and contribute to a safer and more reliable
transportation ecosystem.

Suggestions for Future Work

To improve the overall efficiency of the sensor-based pneumatic bumper

system, the accuracy and speed of the object detection model can be enhanced.
Training the sensor model with a more diverse dataset, including different lighting
and weather conditions, will help improve its ability to detect obstacles in real-
world scenarios. Incorporating multi-sensor fusion, such as integrating LiDAR or
radar along with ultrasonic sensors, will provide better obstacle detection and
depth perception, especially in low-visibility conditions like fog or nighttime
driving.
 Enhancing the pneumatic mechanism to adapt dynamically to different
collision scenarios will improve its effectiveness. An adaptive pneumatic control
system can be developed to adjust air pressure based on the severity of an
impending collision, ensuring a more controlled impact absorption. Conducting
crash simulations using Finite Element Analysis (FEA) will help optimize the
design for maximum impact absorption while minimizing deformation.

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