CHAPTER 1
INTRODUCTION
There have been a notably increasing number of inconveniences let alone untimely
expenses caused by tyre problems, including and not limited to increased fuel consumption.
Majority of scenarios have been where one fails to make it to work or to an appointment in
time due to a flat tyre and on top of that is forced to fish out money to get the car operational
again simply due to tyre pressure issues. Many drivers do the routine of passing through a
pressure refilling point every morning before they get to work which is a both inconvenient
and expensive way to maintain tyres, and as such some drivers choose to ignore under
inflated tyres. Unfortunately they do not know that in doing so they increase the overall fuel
consumption of the vehicle. The instauration of a proper and automated tyre pressure
inflation system would be an innovational advent that would answer to the many vehicle
hustles related to tyre pressure systems currently being faced, incidentally reducing tyre
repair costs by 28%. The under inflation of vehicle tyres attribute to high maintenance cost of
the tyres, elevated fuel consumption and inconveniences or holdups to the user which has
negative effects on finances and it causes delays to work and other appointments.
Improperly inflated tyres are fairly common problems on passenger vehicles. In fact,
80% of passenger vehicles on the road have at least one under-inflated tyre and 36% of
passenger cars have at least one tyre that is 20% or more under-inflated. Often pressure loss
in tyres is a result of natural permeation of the gas through the elastic rubber, road conditions
(such as potholes), and seasonal changes in temperature (According to Weissler of Popular
Mechanics, for every drop of 10 F, tyre pressure drops by 1 psi). Most vehicle owners are
unaware of the fact that their tyres are not at the correct pressures because it is difficult to
determine the tyre pressure visually; a tyre that is properly inflated to the correct pressure
looks very similar to one that is either over-inflated or under-inflated. According to the
Rubber Manufacturing Association (RMA) survey, 80% of people are unsure of how to
check their tyre pressures. Thus, from the viewpoint of passenger vehicle owners, they are
losing money due to increased tyre wear and decreased fuel efficiency, and a solution needs
to be found to correct this issue. From the viewpoint of the designers, however, the root
cause of improperly-inflated tyres is due to vehicle owners not knowing proper tyre pressures
for certain conditions, difficulty finding an air pump, lack of pressure measuring device, and
a general lack of concern. Thus, the combination of the user and expert viewpoints will be
used to make decisions in our design process of this product.
Figure 1.1: Tyre Wear Patterns Observed For Different Tyre Inflation Pressures
Under-inflated tyres tend to show wear on the outside edges of the tread as shown in
fig, while overinflated tyres show wear down the middle of the tread. With incorrect inflation
pressure more tyre wear and thus there is a need to change tyre quickly.
The main motivation for properly inflated tyre is to distribute the vehicle load evenly
across the tyre footprint thereby providing good contact with the road, passenger comfort,
responsive handling and uniform tyre wear. It should be remembered that it is the air pressure
inside the tyre that supports the weight of the vehicle. Two situations can arise with
improperly inflated tyres namely, under-inflated and over-inflated.
In the case of under-inflated tyres, the tyre life could be reduced considerable if the
tyre pressure is maintained low for long periods of time. Tyre manufacturers Michelin and
Goodyear have claimed a reduction in tyre life of up to 30% if tyres are operated 20% below
recommended pressure. Tyre also bends and distorts more, resulting in over-heating and
increased RR. In a test conducted, it was even found that the vehicle was a few seconds
slower around a track on under-inflated tyres, with drivers reporting a detached feeling from
the vehicle in the corners. For the over-inflated case, the tyre could sustain damage when
riding over road surface irregularities such as potholes and bumps. Passenger comfort is also
marginally compromised. Increasing the tyre pressure results in a decrease in tyre-road
contact area, resulting in slightly poorer traction and braking capabilities. Figure 1.1 shows
typical tyre wear patterns observed for under-inflated, recommended and over-inflated tyres.
An under-inflated tyre tends to wear at the shoulders more than at the center, since the
pressure is not sufficient at the tyre center to bear the load. For over-inflated tyres, the wear
is severe along the center due to bulging of the tyre. Proper tyre pressure becomes
particularly important in wet weather conditions from a safety point of view. Tread depth,
tyre footprint size and tread design play a vital role in determining the hydroplaning
characteristics and wet traction performance of a tyre. From a series of test conducted by
Michelin it was concluded that the tyre pressure plays an important role in determining the
tyre's contact patch surface area, especially at increasing vehicle speeds. Tests revealed that
an under-inflated tyre would hydroplane at speeds lower than well inflated tyres for the same
height of standing water.
Inflated tyres naturally lose pressure over time. Not all tyre-to-rim seals, valve-stem-
to-rim seals, and valve seals themselves are perfect. Furthermore, tyres are not completely
impermeable to air, and so lose pressure over time naturally due to diffusion of molecules
through the rubber. Some drivers and stores inflate tyres with nitrogen (typically at 95%
purity), instead of atmospheric air, which is already 78% nitrogen, in an attempt to keep the
tyres at the proper inflation pressure longer. The effectiveness of the use of nitrogen vs. air as
a means to reduce the rate of pressure loss is baseless, and has been shown to be a bogus
marketing gimmick. One study noted a 1.3 psi (9.0 KPA; 0.090 bar) difference (from an
initial pressure of 30 psi (210 KPA; 2.1 bar) for air-filled vs. nitrogen-filled tyres. The test
showed an average loss of 2.2 for the nitrogen filled tyres compared to 3.5 for the air filled
tyres. However, the statistical significance of the test was not given as no t-test nor p values
were reported. And they do note that the loss in both the nitrogen filled tyres and the air filled
tyres mean that tyre pressures should be checked regularly.
The tyre contact patch is readily changed by both over- and under inflation. Over
inflation may increase the wear on the center contact patch, and under inflation will cause a
concave tread, resulting in less center contact, though the overall contact patch will still be
larger. Most modern tyres will wear evenly at high tyre pressures, but will degrade
prematurely if underinflated. An increased tyre pressure may decrease rolling resistance, and
may also result in shorter stopping distances. If tyre pressure is too low, the tyre contact
patch is greatly increased. This increases rolling resistance, tyre flexing, and friction between
the road and tyre. Under-inflation can lead to tyre overheating, premature tread wear, and
tread separation in severe cases
The materials of modern pneumatic tyres are synthetic rubber, natural rubber, fabric
and wire, along with carbon black and other chemical compounds. They consist of a tread
and a body. The tread provides traction while the body provides containment for a quantity of
compressed air. Before rubber was developed, the first versions of tyres were simply bands
of metal fitted around wooden wheels to prevent wear and tear. Early rubber tyres were solid
(not pneumatic). Today, the majority of tyres are pneumatic inflatable structures, comprising
a doughnut-shaped body of cords and wires encased in rubber and generally filled with
compressed air to form an inflatable cushion. Pneumatic tyres are used on many types of
vehicles, including cars, bicycles, motorcycles, buses, trucks, heavy equipment, and aircraft.
Metal tyres are still used on locomotives and railcars, and solid rubber (or other polymer)
tyres are still used in various non-automotive applications, such as some casters, carts,
lawnmowers, and wheelbarrows.
Lowering a vehicle in conjunction with low-profile tyres can also negatively affect
wheel alignment. The modified lever arms (e.g. less rim offset after retro fitting) encourage a
tendency for the alignment of the wheels to deviate during driving from the specified data.
This might go unnoticed as all wheel alignment values are still found to be within
tolerance limits when measured statically on the axle measurement bench. The result may be
an increase in non-uniform wear.
1.5.5 TESTING
This phase includes testing of system performance, which include testing tyre
pressure while running condition as well as in stationary position of vehicle for different
times.
CHAPTER 2
LITERATURE SURVEY
2.1Literature Survey:
Literature Survey including journals, conference proceedings, trade magazines,
government reports, market, consumer and product information about existing methodologies
has been carried out with the help of electronic searches. This search is conducted to identify
the different tyre pressure inflation systems existing in the market and also to find out similar
products in other areas, which will help the current product development. The patents survey
was also carried out to collect information about available patent pertaining to the area of
interest for study and understanding.
V.JeevaBharathi developed automatic tyre inflation and deflation system. This can
be placed in all automobiles while long drives and that can be utilized while climbing uphill
or down hills. It is very necessary for the every automobile to be cautious while driving
through long distances. So they have fabricated this machine to fill the air automatically by
using control units. In this project main function is suddenly the air is decreased to the
automobile vehicles the sensor signal alerted to the person when the use of air tank to fill the
air in the tyre. Then the air pressure is increased to the tyre in the vehicle it is same as the
process of indicating the sensor signal through the person when the use of solenoid valve to
reduce the excess air in the tyre.
Senthilraja applied the techniques to reduce the process time and human efforts of
the conventional manual air filling system. The system helps to reduce cost and
frictionbetween surface of tyre and road so that will reduce thewastage of tyre material. As a
result, Itwill increase the life of tyre. After fabrication of automatic tyre inflation system, the
result obtained that if the system utilization will be executed in proper by taking and
concerning all the relevant according to the project demand the process time, cost and human
efforts can be reduce in a great manner.
TawandaMushiri presented in their report the functions to restore the tyre pressure
on vehicles so that they are kept at optimum pressure levels, thus extending their life time at
the same time saving the owner from fuel costs and maintenance cost incurred with
underinflated tyres. It constitutes of a wind driven turbinecompressor unit which uses drag
Dept of Mechanical Engg, NIEIT Mysuru Page 10
Fabrication of Automatic Tyre Pressure Inflation System
wind as source of drive to a turbine and quickly converts it to rotational energy which powers
a small compressor that feeds the tyre with pressurized air whenever the need arises. The
system is monitored and controlled by a Java/Android program which detects low pressure
and initiates compressor ON / OFF states. The system is environmentally friendly releasing
zero gases and is self-sustaining using independent power source from that of the vehicle
itself.
The aim of this study is to design and fabricate a system in which there is proper
inflation in the tyre at all times which produce fuel savings of 1-4% and increase tyre life by
up to 10%. A trial was done in this case paper involving two cement tankers in NSW
Australia operated over a period of 12 weeks in 2013. For first 6 weeks central inflation
system was turned ON in both tankers and for another 6 weeks central inflation system was
turned OFF in the both and graphs are prepared showing trucks with central inflated system
is good in conditions like average vehicle idle time, average vehicle time spent using power
Dept of Mechanical Engg, NIEIT Mysuru Page 11
Fabrication of Automatic Tyre Pressure Inflation System
take off, average vehicle GHG emissions, average vehicle fuel consumption across the trial
period. Our design proposes and successfully implements the use of a portable
compressor that will supply air to all four tyres via hoses and a rotary joint fixed
between the wheel spindle and wheel hub at each wheel. The rotary joints effectively allow
air to be channeled to the tyres without the tangling of hoses. With the recent oil price hikes
and growing concern of environmental issues, this system addresses a potential
improvement in gas mileage; tyre wear reduction; and an increase in handling and
tyre performance in diverse conditions
CHAPTER 3
3.1 OBJECTIVES
The main objective of the present work is to develop and demonstrate automatic tyre
inflation system for two wheelers to overcome the difficulty of under inflation.
1) Maintains the required tyre pressure:
The function of the system is to maintain and adjust the pressure in all the tyres of
the system according to varying loading and driving conditions.
2) An Automatic System:
An automatic system further saves human energy & time in filling the air in tyres
when they are in under inflated conditions.
3) Builds a Low cost system:
The installation of such a system in vehicles is a low cost affair.
3.2 METHODOLOGY
The following steps were carried out to achieve the objective of the project work
Problem Identification
Concept Development
Prototyping
Underinflated tyres overheat more quickly than properly inflated tyres, which cause
damage to tyres. To reduce this problem we are designing this system. As soon as a tyre
pressure goes under inflated, then a pressure sensor senses it and send it to the Controller
which activates the solenoid valve and air is filled up to proper inflation. To develop an
automatic air filling system which recognizes and fills air in respective tyre when its pressure
goes below the desired/required pressure (under inflated condition).
air into the tyre and maintain a constant pressure. Some of the major components used to
develop the system are
12V DC compressor
12V 2/2 Solenoid Valve
Strain gauge type pressure switch
Analog type pressure gauge
Quick release rotary joint
12V dry battery
Flexible air hose
1/2 inch T- Valve
Working Principle
This mechanism works on the principle that the compressor supplies air to the tyre when the
vehicle is running as well as in stationary. The air from the compressor is supplied to the
rotary joint, from where the air is supplied to the tyre which is under-inflated because of the
implementation of rotary joint the air is easily supplied to the tyre without tangling the hoses.
An automatic compact air compressor, shutdown automatically when the required tyre
pressure is reached. In the process of automatic tyre inflation system as shown in fig. The
compressor is used to compress the air. The air is taken from the atmosphere and compressed
it at required pressure. There is ducting which is used connect to the compressor outlet port
and one end of the rotary joint. The compressed air is supplied to the rotary joint through the
ducting. Two Pedestal bearings are used to support the axle of the assembly. Bearings are
fixed to the rigid supports via nuts and bolts. The axle is rotate on which wheel or rim is
mounted on one end. One end of coupler is connected to axle and other end is connected to
rotary joint.
A Compressed air is given to the 2/2 solenoid valve inlet through Air compressor.
The pressure switch is used to sense the tyre pressure. The required tyre pressure is set in the
pressure switch reading. This pressure switch is used to sense the current pressure and this
output signal is given to the solenoid valve. Whenever the tyre pressure is below the set valve
the pressure switch activate the solenoid valve. The compressed air goes to the tyre with the
help of quick release coupling which is used to rotating the wheel freely. Once the required
pressure is reached in the tyre, the pressure switch will deactivates the solenoid valve so that
the tyre pressure will be maintained in constant level.
3.3.3 Prototype
As per the concept developed and with the materials selected, a working model is
developed as show in figure. The working prototype is mounted on a real time bike (TVS
Super). This prototype is used to check its workability and performance for infiltrating tyre in
both static and dynamic conditions. It is mounted to the front tyre of the bike with little
modifications on the front side.
CHAPTER 5
MATERIAL SELECTION
The following materials are selected to build the prototype as per the concept developed.
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
air, steam, water, thermal oil, hydraulic fluids etc. 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.
Specifications:
An air compressor is a device that converts power (using an electric motor, diesel or
gasoline engine, etc.) into potential energy stored in pressurized air (i.e., compressed air). By
one of several methods, an air compressor forces more and more air into a storage tank,
increasing the pressure. When tank pressure reaches its upper limit the air compressor shuts
off. The compressed air, then, is held in the tank until called into use. The energy contained
in the compressed air can be used for a variety of applications, utilizing the kinetic energy of
the air as it is released and the tank depressurizes. When tank pressure reaches its lower limit,
the air compressor turns on again and re-pressurizes the tank.
Specifications:
A pressure switch is a form of switch that closes an electrical contact when a certain set fluid
pressure has been reached on its input. The switch may be designed to make contact either on
pressure rise or on pressure fall. Pressure switches are widely used in industry to
automatically supervise and control systems that use pressurized fluids.
Specifications:
Enclosure Plated Steel with ABS cover to IP:33 as per IS:13947 (Part-I), 1993
Sensing Element Photoshop Bronze Bellows
Switching Instrument Quality snap acting microswitch-SPDT contacts
Switch Rating 15A 250V AC
Repeatability / Accuracy + 2% FSR
Ambient Temperature 70 c
Process Temperature 100 c max
Prcess Connection 1/4" BSP (F)
Dept of Mechanical Engg, NIEIT Mysuru Page 20
Fabrication of Automatic Tyre Pressure Inflation System
Instruments used to measure and display pressure in an integral unit are called pressure
gauges or vacuum gauges. A manometer is a good example as it uses a column of liquid to
both measure and indicate pressure. Likewise the widely used Bourdon gauge is a
mechanical device which both measures and indicates, and is probably the best known type
of gauge.
Specifications:
An electric battery is a device consisting of one or more electrochemical cells with external
connections provided to power electrical devices such as flashlights, smartphones, and
electric cars. When a battery is supplying electric power, its positive terminal is the cathode
and its negative terminal is the anode
Type: Dry
Voltage: 12V
Current: 12Ah
Air hoses are used in underwater diving, such as scuba diving, to carry air from the surface or
from air tanks or diving pumps to the diver. Air hoses are therefore a necessary part of
standard diving dress and any type of surface supplied diving equipment. They are an
essential part of scuba diving equipment, used to deliver pressurised air from the first stage of
a diving regulator to the other components.
Specification:
Inner Diameter: 8 mm
Outer Diameter: 14 mm
Working Air pressure: 300 PSI
Burst Air Pressure: 1200 PSI
CHAPTER 6
The most important advantage is you dont have to stop in any area where you cant
find help if tyre get punctured, as you get solution for such problem by yourself.
Another important advantage of this system is that you dont need to check tyre
pressure at any air filling station. Thus never have to go anywhere for the air filling.
As the required pressure in tyres is always maintained, the life of tyres increases.
Also the efficiency and mileage of the vehicle increases which eventually saves the
money of owner.
You dont have to change your tyre with another tyre which saves a lot of time and
you can utilize that time in reaching to your destination.
The overall weight of this system is also very less so that this system can also be
effectively implanted in cars,buses, trucks etc.
The next major advantage is withstanding the static and dynamic loading exerted on
the rotary joints.
The most important is pressure adjustment based on increasing vehicle speed and
load. Hence reduced in tyre wear.
The cost of system is optimum, but increases fuel economy and overall vehicle
safety.
6.2DISADVANTAGES
It needs a separate unit to install components.
It needs power supply
Requires more maintenance
Too many components
Heavier than general vehicles
6.3APPLICATIONS
Automobile Application
Car Manufacturing Industry
All two wheeler and four wheeler applications
CHAPTER 7
The below table is the observation made on the system at various conditions
CHAPTER 8
CONCLUSION
The Self-inflating tyre system would be capable of succeeding as a new product in the
automotive supplier industry. It specifically addresses the needs of the consumers by
maintaining appropriate tyre pressure conditions. Because such a product does not currently
exist for the majority of passenger vehicles, the market conditions would be favorable for the
introduction of a self-inflating tyre system.
We can conclude that this automatic self-inflating tyre system ensures that all tyres are
always properly inflated and thus improves the tyre life, safety 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.
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