Three Axis Pneumatic Modern Trailer

Transcription

1 Three Axis Pneumatic Modern Trailer Fazaludheen Chemmala [1],Abdul Fahad P [2], Abdul Rashik K [3], Aflah K [4], Ameer Sadath Kt [5], Arshad Mohammed K [6] [1] Assistant Professor (Internal Guide) -Department of Mechanical Engineering-Eranad Knowledge City-Technical Campusmanjeri Malappuram-Kerala [2][3][4][5][6] Students- Department Of Mechanical Engineering- Eranad Knowledge City-Technical Campusmanjeri Malappuram-Kerala Abstract This project work titled Three axis pneumatic modern trailer has been conceived having studied the difficulty in unloading the materials. Our survey in the regard in several automobile garages, revealed the facts that mostly some difficult methods were adopted in unloading the materials from the trailer. The trailer will unload the material in only one single direction. It is difficult to unload the materials in small compact streets and small roads. In our project these are rectified to unload the trailer in all three sides very easily. Now the project has mainly concentrated on this difficulty, and hence a suitable arrangement has been designed. Such that the vehicles can be unloaded from the trailer in three axes without application of any impact force. By pressing the direction control valve activated,the compressed air is goes to the pneumatic cylinder through valve. The ram of the pneumatic cylinder acts as a lifting the trailer cabin. The automobile engine drive is coupled to the compressor engine, so that it stores the compressed air when the vehicle running. This compressed air is used to activate the pneumatic cylinder, when the valve is activated. Index Terms Link Mechanism, Modern Trailer, Pneumatic system, Three Axis, Tipper Lorry, Truck, valves. 1 INTRODUCTION A Trailer or dumper is a vehicle designed for carrying bulk material, often on building sites. Dumpers are distinguished from dump trucks by configuration. It is usually an open 4-wheeled vehicle with the load skip in front of the driver, while a dump truck has its cab in front of the load. The skip can tip to dump the load; this is where the name "dumper" comes from. Modern trailers have payloads of up to 10 tones and usually steer by articulating at the middle of the chassis (pivot steering). They have multi-cylinder diesel engines, some turbocharged, electric start and hydraulics for tipping and steering and are more expensive to make and operate. An A-frame known as a ROPS (Roll Over Protection) frame may be fitted over the seat to protect the driver if the dumper rolls over. Some dumpers have FOPS (Falling Object Protection) as well. Lifting skips are available for discharging above ground level. Dumpers are the most common cause of accidents involving construction plant. A trailer is an integral part of any construction work and hence its role is important for completion of any constructional site works. One of the problems cited with dumper is the problem during unloading in narrow roads and mines where it is impossible to unload the materials to the sides. Hence the need of the project work raised which is about 3 way dropping trailer which can dump the material in any direction except the frontal one without moving the truck in any direction. 2 LITERATURE REVIEW Amboji Sudhakar Retal studied that trailer has lots of applications in today s world. In industrial and domestic considerations, trailer can haul a variety of products including gravel, potatoes, grain, sand, compost, heavy rocks, etc. By considering wide scope of the topic, it is necessary to do study and research on the topic of tipper mechanism in order to make it more economical and efficient. In existing system, trailer can unload only in one side by using hydraulic jack or conveyor mechanism. By this research it is easy for the driver to unload the trailer and also it reduces time and fuel consumption. For making trailer mechanism with such above conditions both mechanisms namely hydraulic jack and conveyor mechanism ISSN: Page 45

2 can be used. But eventually it comes with question that how both systems can arrange in single set up? Answer to this question is nothing but this research work. [1] Record shows one of the first hydraulic dump bodies was the Robertson Steam Wagon with a hydraulic hoist that received power from the truck s engine or an independent steam engine. Alley &McLellan of Glasgow developed another early hydraulic dump body in 1907 that was power-driven by steam. [2] The dump truck was first conceived in Saint John, New Brunswick when Robert T. Mawhinney attached a dump box to a flat bed truck in The lifting device was a winch attached to a cable that fed over sheave (pulley) mounted on a mast behind the cab. [2] Euclid was a pioneer in the development of dump trucks. George Armington Jr., son of founder George Armington, was a hydraulics designer and made two significant contributions to the world of dump trucks. These included the modern heavy duty off-highway truck and the wheel tractor bottom dump wagon. [3] 3 REQUIREMENT STUDY ANAYSIS 3.1 HISTORY The very first version of a dump truck used to haul and dump material was nothing more than a simple dump body style cart drawn by horses. It would have consisted of a twowheeled cart hinged to the axle with the center of gravity, when loaded, just behind the axle. The loaded front body was hooked, and when unlatched, would dump. These carts were used in open mines and pulled by horses along a railway track. After 1900, a four-wheeled horse-drawn flatbed wagon with a rectangular body lifted with a hand hoist in the front was employed. In the book, 500 Years of Earthmoving, Heinz Herbert Cohrs cites that before the first dump trucks appeared, excavated materials were being removed and hauled by locomotives and trolleys known as box tip wagons, dump bodies, and scoop tippers Early Truck Mounted Dump Bodies: The earliest versions of truck mounted dump bodies relied on the principle of gravity for dumping. The dump body pivoted off center and, when level, would be locked in place. Releasing the lock would activate the body to dump to the rear. The dump body, when empty, remained locked in a nondumping position. When loaded, the dump body s centre of gravity would shift, activating it to dump. Some of the first trucks with dump bodies designed on this principle appeared as early as 1904 when the Mann gravity dump was built in England Hydraulic Dump Bodies: Hydraulics was being incorporated into truck mounted dump bodies relatively early on. Records show that one of the first hydraulic dump bodies was the Robertson Steam Wagon with a hydraulic hoist that received power from the truck s engine or an independent steam engine. Alley & McLellan of Glasgow developed another early hydraulic dump body in 1907 that was power-driven by steam Crawler Tractor-Trailer: In the middle of the 1920s, crawler tractors pulling heavy dump trailers mounted on wheels or tracks were becoming increasingly popular. Sometimes crawlers would pull two to five attached trailers. Companies began developing wagons specifically designed for attachment to crawler tractors. The first versions were mounted on tracks; however, when speed restrictions posed a problem, the wagons were mounted on wheels to improve speed. Manufacturers of such trailers and haulers included Euclid, James Hagy, LaPlant-Choate, Rex- Watson, and Streich and Western Euclid Dump Trucks: Euclid was a pioneer in the development of dump trucks. George Armington Jr., son of founder George Armington, was a hydraulics designer and made two significant contributions to the world of dump trucks. These included the modern heavy duty off-highway truck and the wheel tractor bottom dump wagon. In 1934 the company introduced its 10/11-ton dump truck called the "TrakTruk." It was the first rear-dump truck that was designed for heavy-duty off road service. This was followed up in 1936 with the company s 15-ton Model IFD truck that featured a diesel engine, modern drive line, planetary final drives, leaf-spring suspension, and pneumatic tires. The truck replaced heavy, gasoline powered chain drive Mack trucks that had previously been used for standard work in construction and mining operations. ISSN: Page 46

3 Another prominent development was the launch of Euclid s wheel tractor bottom dump wagon combination. The wheel tractor bottom dump had haul road speeds of 30 miles per hour (48 km) and extended haul distances beyond what was ever considered economically feasible. Along, with Le- Tourneau, stournapull, the Euclid bottom dump was a major advancement in earthmoving Dump Trucks in the 1950s: By the 1940s the technological development of dump trucks had reached its peak. In the U.S., bottom dump trucks were already dominating earthmoving sites by the 1950s. As the industry moved away from a reliance on rail operations to haul material, the need for domestically produced construction site tippers began to emerge. One of the heavyduty dump trucks manufactured during this time was by Faun. The truck could carry up to 20 tons and was powered with a 180 horsepower engine. The dump trucks were considered off-highway dump trucks because of their width and axle weights Saint John First: The dump truck was first conceived in Saint John, New Brunswick when Robert T. Mawhinney attached a dump box to a flat bed truck in The lifting device was a winch attached to a cable that fed over sheave (pulley) mounted on a mast behind the cab. The cable was connected to the lower front end of the wooden dump box which was attached by a pivot at the back of the truck frame. The operator turned a crank to raise and lower the box. Today, virtually all dump trucks operate by hydraulics and they come in a variety of configurations each designed to accomplish a specific task in the construction material supply chain. 3.2 TYPES OF DUMP TRUCKS A dump truck is a truck used for transporting loose material (such as sand, gravel, or demolition waste) for construction. A typical dump truck is equipped with an open-box bed, which is hinged at the rear and equipped with hydraulic pistons to lift the front, allowing the material in the bed to be deposited on the ground behind the truck at the site of delivery. World demand for resources is growing and is recovering rapidly from the effects of the economic recession that followed financial crisis and which in any case were quite small. Today, virtually all dump trucks operate by hydraulics and they come in a variety of configurations each designed to accomplish a specific task in the construction material supply chain Standard Dump Truck: A standard dump truck is a truck chassis with a dump body mounted to the frame. The bed is raised by a hydraulic ram mounted under the front of the dumper body between the frames, and the back of the bed is hinged at the back to the truck. The tailgate can be configured to swing on hinges or it can be configured in the "High Lift Tailgate" format wherein pneumatic rams lift the gate open and up above the dump body Articulated Dump Truck: An articulated dump truck, or "Yuck" in the construction world, has a hinge between the cab and the dump box Steering is accomplished via hydraulic rams that pivot the entire cab, rather than rack and pinion steering on the front axle. This vehicle is highly adaptable to rough terrain. In line with its use in rough terrain, longer distances and overly flat surfaces tend to cause driveline troubles, and failures. Articulated trucks are often referred to as the modern scraper, in the sense that they carry a much higher maintenance burden than most trucks. See the first mass produced articulated dump truck (articulated hauler) Semi Trailer End Dump Truck: A semi end dump is a tractor-trailer combination wherein the trailer itself contains the hydraulic hoist. A typical semi end dump has a 3-axle tractor pulling a 2-axle semitrailer. The key advantage of a semi end dump is rapid unloading. A key disadvantage is that they are very unstable when raised in the dumping position limiting their use in many applications where the dumping location is uneven or off level. 3.3 EXISTING SYSTEM A conventional dump truck is mounted on a truck chassis and has an open dump box hydraulically operated and hinged at the rear of the truck usually by one or more hydraulic rams that raise the dump box to unload contents at a delivery site. These hydraulic rams are either front loaded or mounted in the underbody and are driven from a gear box power takeoff. Hydraulic rams mounted in the underbody provide the ISSN: Page 47

4 capability of the dump body to tip the dump box on a threeway basis, either to the left or right side or to the rear. The tipping mechanism is the heart of a three way tipper construction truck. Tipping mechanisms work basically on the following: Hydraulic cylinder: A hydraulic cylinder is placed below the body of truck longitudinally at one end of the truck, and the piston end of the hydraulic cylinders is connected by the means of a pivot joint to the chassis of truck. cylinders one on cabin side (as in existing system), one each on lateral sides. Six hinges- 2 on each side to give degree of motion on that side. The framing will be rigid enough to sustain the reactive forces generated, refer the attached picture of 3-way tipper arrangement. Main hydraulic cylinder is placed at middle of front side of chassis i.e. 1 for back side tilting of the trolley and other two (2,3) cylinders are placed on along lateral side of the chassis at appropriate distance for left and right side tilting of the trolley. Fig 3.1 Four Hydraulic Cylinder Model In the forward stroke of the cylinder, it pushes the truck body upward thus gives necessary lift for tipping dumping. So, in the forward stroke of the cylinder, the truck is unloaded. In the return stroke of the cylinder the body of the truck comes to its original position Hinge Joint: The other bottom end of the body of the truck is connected by a hinged joint with the chassis. These are specially designed hinges which are capable of withstanding high force. Fig 3.2 Hinge joint Three way tipper mechanism: Three way tipper can unload materials in all three sides. Also we require special types of hinge joints in this case as mentioned earlier. It will be having three hydraulic piston Fig 3.3 Hydraulic three cylinder model Trolley is connected with chassis with the help of six hinges.two hinges on each lateral side for left and right side tilting of trolley, two hinges on back side of chassis for back side tilting of trolley. Above figure 3.4 shows the hinge position. Now with this mechanism it is possible to tilt trolley on all three sides i.e. back, left and right side. For backside dumping of material, hydraulic cylinder no. 1 is in operation and hinge no.h1,h2,h5 and H6 must be disconnected manually by pulling pin from the hinge, for this hole of 8 mm. diameter is provided on pin head to facilitate manual pulling by inserting rope inside the pin hole. For this operation cylinder 2 and 3 are not in working. The maximum angle of turn made by trolley with horizontal for effective backside unloading of loose material is 45 degree. For right side dumping of material hydraulic cylinder no. 2 i.e. left side cylinder is in operation and hinge no. H1, H2, H3, and H4 are to be disconnected manually by pulling pin from the hinge. For this operation cylinder 1 and 3 are not in working. The maximum angle made by trolley with horizontal for effective right side unloading of loose material is 200.Same procedure is adopted for left side dumping of material only change is with hinge disconnection i.e. H3, H4, H5 and H6 are disconnected and hydraulic cylinder no.3 i.e. right side cylinder is in operation. Other two cylinders are in not working position. Hydraulic cylinder 2 and 3 is not directly connected with the trolley; on the top of the cylinder cushion- ISSN: Page 48

5 ing pad is provided to push the trolley, for side tilting and at the time of return stroke due to self-weight trolley will come to its initial position. 3.4 THREE AXIS PNEUMATIC MODERN TRAI- LER In this modern three axis pneumatic trailer system, the air circuit plays a vital role in the system and it is necessary to understand the movement and working principle of the air circuit. The figure below shows the circuit diagram of the modern three axis pneumatic modern trailer. The air which is compressed in the compressor is sent to the direction control valve. The 2 direction control valve will change the flow direction of the compressed air depending on the handle valve position. Then the compressed air from the direction control valve is sent to the cylinder block depending on the valve position. The compressed air admitted in the cylinder block will push the piston upwards. The piston stroke length can adjusted by means of the operation of hand lever valve position. The lifting of the trailer will be done by three cylinder block attached with the trailer. Mostly adopted systems consist of three or more hydraulic cylinders. So naturally the cost increases. Proposed mechanism is simply based on single pneumatic cylinders which rotates on a plate and do the unloading activity. 4 OBJECTIVES Main objective of the project is to create a dumping truck capable of unloading materials in three sides and if possible, to unload in multi axis. But during modification, following objectives can also be parallely achieved. To achieve high safety To reduce man power To increase the efficiency of the vehicle To reduce the work load To reduce the fatigue of workers To high responsibility Less Maintenance cost 5 METHODOLOGY AND SETUP In this project we are using single cylinder instead of three as per used in current dumping truck. In this we are mounting a pneumatic cylinder on rotating plate which will rotate along with axis. Fig 5.1 Schematic Diagram of Three axis pneumatic cylinder Fig 3.4 Three Axis Pneumatic cylinder 3.5 DISADVANTAGES OF EXISTING SYSTEM Existing trailers requires more space, time and fuel. Moreover, this system is only used in developed countries because of its cost and maintenance problems. The project mechanism has mainly concentrated on the difficulty of loading and hence a suitable arrangement has been designed. Such that the load can be unloaded from the trailer in three axes without application of any impact force. By pressing the Direction control valve activated. The compressed air is goes to the pneumatic cylinder through valve. The ram of the pneumatic cylinder acts as a lifting the trailer cabin. The automobile engine drive is coupled to the compressor engine, so that it stores the compressed air when the vehicle running. This compressed air is used to activate the pneumatic cylinder, when the valve is activated. ISSN: Page 49

6 Pneumatic Three Axis Modern Trailer is nothing but one of the Lifting system in automobile at the time of emergency. In this Lifting system pneumatically operated one. Here the additional pneumatic cylinder and Control Valve is provided in the automobile itself. In this project, the Control Valve is used to activate/deactivate the Air input. The Valve is ON at the time of emergency; the compressed air goes to the pneumatic cylinder. Then the compressed air passes through the tube, and then pushes the pneumatic cylinder, so that the Lifting is applied at the time of Valve in ON position. The speed of the pneumatic cylinder is varied by using flow control valve. This is the way of controlling Lifting speed of the Trailer at the time of emergency. In our project, we have to apply Pneumatic Modern Trailer Mechanism in Load Lifting Vehicles. The Control Valve is fixed in near of the driving persons in the four wheels. The air tank contains the compressed air already filled. The Valve was ON at the time of emergency, the Control Valve was activated. The compressed air flow is controlled by the valve. Then the compressed air goes to the pneumatic cylinders. The pneumatic cylinders piston moves forward at the time of compressed air inlet to the cylinder. Fig 6.1 Single Acting Cylinder They are almost universal in internal combustion engines (eg: petrol engine and diesel engine) and are also used in external combustion engines like Stirling engine Double Acting Cylinder: Double acting cylinders are kind of cylinders in which the working fluid acts alternately on both sides of piston. Double acting cylinders are most common in steam engines. 6 DESCRIPTION OF EQUIPMENTS 6.1 PNEUMATIC CYLINDER: Pneumatic cylinders are the operating devices which convert energy of compressed air into mechanical output. Cylinder used in the process is a double acting pneumatic cylinder with 40 mm internal diameter and 45 mm external diameter and with a stroke length of 120 mm. The cylinder compresses air moves the piston in two directions. Cylinders are generally classified as single acting cylinders and double acting cylinders Single acting cylinder: Single acting cylinder is only capable of performing an operating medium in only one direction. They depend upon load, spring, or momentum of flywheel to push the piston back in other direction. They are usually found in most kinds of reciprocating engines. Fig 6.2 Double Acting Cylinder Double acting hydraulic cylinders are used where an external force is not is not available to retract the piston or where high force is required in both directions of piston travel. 6.2 FLOW CONTROL VALVE: In any fluid power circuit, flow control valve is used to control the speed of the actuator. The flow control can be achieved by varying the area of flow through which the air in passing. When area is increased, more quantity of air will be sent to actuator as a result its speed will increase. ISSN: Page 50

7 rotates. Fig 6.3 Control Valve 6.3 AIR COMPRESSOR: Air compressor is used to compress the air and increase its pressure. In this setup, automobile engine drive is coupled to the compressor engine, so that it stores the compressed air when the vehicle running. This compressed air is used to activate the pneumatic cylinder, when the valve is activated. Fig 6.5 Spur Gear 6.5 DC MOTOR: A DC Motor is a simple working device which converts electrical energy directly into mechanical energy by the principle of electromagnetic induction. DC Motor used here is of 12 V, 60 RPM having 7 teeth and it is used to rotate the gear. Motor has a load carrying capacity of maximum 50 Kg.. Fig 6.4 Air Compressor 6.4 GEAR: Spur gears or straight-cut gears are the simplest type of gear. The edge of each tooth is straight and aligned parallel to the axis of rotation. These gears mesh together correctly only if fitted to parallel shafts. No axial thrust is created by the tooth loads. Spur gears are excellent at moderate speeds but tend to be noisy at high speeds.a spur gear with 100 mm diameter and 58 teeth is the main component in this project. The rotating plate is placed upon this gear. The motor connected to this gear help in gear rotation which in turns helps in the disc rotation and thus the entire body of the load cab Fig 6.6 DC Motor 6.6 ROTATING DISC: Rotating disc used in this project is a cast iron piece. This is the one which cause the rotary motion of the cabin. Running through the center of the rotating disc is a metallic shaft whose end is directly connected to the spur gear and that is how the rotation is made possible. ISSN: Page 51

8 Fig 6.7 Rotating Disc 6.7 BATTERY: Battery used is a 12V, 7A Lead Acid battery. Lead acid batteries plays significant role in automobile motors. Despite having a very low energy-to-weight ratio and a low energy-to-volume ratio, its ability to supply high surge current means that the cells have a relatively large power to weight ratio. These features, along with their low cost, make it attractive for use in motor vehicles to provide the high current required by automobile starter motors Fig 7.1 Assembled Model When the DC Motor which is connected to the spur gear is operated using a battery, the gear rotates and thus the rotating disc also rotates. Since the load cabin is directly connected to the rotating disc, it also rotates When the load cabin reaches at the place where the load has to be dumped, the toggle switch is activated. During the forward stroke of the cylinder, it pushes the truck body upward thus giving necessary lift for dumping. So, in the forward stroke of the cylinder, the truck is unloaded. In the return stroke of the cylinder the body of the truck comes to its original position. Fig 6.8 Battery 7 EXPERIMENTATION Working of a three axis modern pneumatic trailer is based on the double action of pneumatic cylinder and rotation of the gear. The automobile engine drive is coupled to the compressor engine, so that it stores the compressed air when the vehicle is running. This compressed air is used to activate the pneumatic cylinder, when the valve is activated.the ram of the pneumatic cylinder acts as a lifting the trailer cabin. Fig 7.2 Motor-Gear Arrangement ISSN: Page 52

9 8 ADVANTAGES Repairing is easy. It requires simple maintenance cares Replacement of parts is easy. Increased moving ability: Thus, it does not become tiresome to perform the job. Can be used in very compact places: Where the reversing & turning of vehicle is difficult. Manual power not required Can accommodate into pass on dam site working: Saves time & energy. Handling is easy. Checking and cleaning are easy, because of the main parts are screwed. 9 CONCLUSION A prototype which exhibits the expected results is developed. With analysis of working and with the help of pneumatic system, lifting operations can be easily carried out without much effort. This mechanism is not only applicable in dumping trucks but also for various manufacturing industries. Thus we have developed a Three Axis Pneumatic Modern Trailer which helps to know how to achieve low cost automation. The operating procedure of this system is very simple, so any person can operate. By using more techniques, they can be modified and developed according to the applications. Further modifications and working limitations will put this work in the main league of use. 9.1 FUTURE SCOPES Modification on current system can be possible. Providing ball and socket joint or universal joint at the tip of pneumatic cylinder piston, using external compressor, introduction of single hydraulic cylinder instead of pneumatic etc can make the system a little more efficient. Another change that can be made is to introduce some rollers in between the load cabin and the body of the vehicle. This setup will make the rotation of the load cabin easier and thus the rotating disc will no longer have to experience the complete load. Overall, Three Axis Modern Pneumatic Trailer will play an important role in coming generation. ACKNOWLEDGMENT We would remember with grateful appreciation, the encouragement and support rendered by the Principal Dr.B Priestly Shan of Eranad Knowledge City, Manjeri. We express our deepest sense of gratitude to Head of the Department Mr.Saleem N and our internal guide Mr.Fazludheen Chemmala, Assistant Professor, Mechanical Engineering for their willingness and readiness in giving valuable advice and guidance. We would always oblige for the helping hands of all other staff members of the department and all our friends and wellwishers, who directly or indirectly contributed in this venture. Last but not least, we are indebted to God Almighty for being the guiding light throughout this project and helped us to complete the same within the stipulated time. REFERENCES [1] Design and Fabrication of Three Way Tipper Mechanism- International Journal of Research in Advent Technology, Vol.2, No.4, April 2014-Amboji Sudhakar, Humane Yogesh,Chavan Rohan,PatilJyotsna, KshirsagarPrashant R. [2] Dump Trucks Motor Books International. pp ISBN by Donald F. Wood [3] Moving the Earth: The Workbook of Excavation - Fifth Edition, (2005) McGraw-Hill Companies, Inc.by Nichols, Herbert Lownds; Day, David A. [4] Design of Multiside Tipper Tilting Mechanism- 15-th National conference on Machines and Mechanism- Hemant A. Gaikwad, Nilesh P. Awate [5] Design and Development of 3-Way Dropping Dumper- International Journal of Emerging Technology and Advanced Engineering Website: Volume 4, Issue 9, September 2014) - Ganesh Shinde1, Prachi Tawele, Laukik Raut [6] A Text Book of Fluid Mechanics and Machinery, Laxmi Publications, NewDelhi, 2000 by R.K.Bansal, Pascal, [7] Backward movement control of a trailer truck system - IEEE conference on Industrial Electronics Society (IECON 2000), vol. 1, 2000, pp By H. Kinjo, B. Wang, and T. Yamamoto, [8] Modeling and Analysis of Tractor trolley Axle using Antsy Design and Fabrication of Unidirectional Dumper - Journal of Mechanical and Civil, E-ISSN ISSN X, Volume Vol. 6, Issue 5 (MAY-JUNE) PP by P. Manasa, C. VijayaB. Reddy. [9] Theory of machines, S. Chand & Company Ltd., New Delhi, 2008 by R.S. Khurmi, J.K. Gupta ISSN: Page 53