Available online at: http://www.ijmtst.com/vol4issue5.html International Journal for Modern Trends in Science and Technology ISSN: 2455-3778 :: Volume: 04, Issue No: 05, May 208 Design and Development of Hydraulic Driven Mobile Air Inflator K.Sethuramalingam V.Arun Kumar 2 U.G.Scholar, Department of Mechatronics Engineering, Kongu Engineering College, Erode, TamilNadu, India 2 Assistant Professor, Department of Mechatronics Engineering, Kongu Engineering College, Erode, TamilNadu, India To Cite this Article K.Sethuramalingam and V.Arun Kumar, Design and Development of Hydraulic Driven Mobile Air Inflator, International Journal for Modern Trends in Science and Technology, Vol. 04, Issue 05, May 208, pp.-08-2. ABSTRACT Tractors and Construction Equipment machines are fitted with a Front End Loader (FEL) and Backhoe Loader (BHO) which are used to load and unload the materials in industries, construction areas and agriculture land etc.,. Mostly these machines are working in agriculture land, forest. So these tyres of machine easily get puncture or minimal air loss. Due to puncture, the machines could not run on the field and it needs workers to carry out the service for the ride. Reassemble of tyre may take minimum of 6 hours including ideal time. So this operation takes more time. During the service period it leads to losses. The machine placed in the field in ideal mode. To overcome this issue, mobile air inflator for tractors and loading machines are to be designed. Both tractors and Construction Equipment Machines has hydraulic energy from pump. So this experimental work needs hydraulic motor to drive a compressor. This power is taken from the machine and then motor starts to rotate with 2500 rpm. Motor is coupled with compressor through belt drive & pulley. From the compressor, compressed air stored in an air tank with a capacity of 300 litre tank. Totally this is an attachment which is fitted on the machine. Whenever the tyre get puncture, Air is filled within the tyre. Hence this air pressure will sustained for a maximum of hour. The work has to be completed and tyre gets to be serviced in a service centre. It reduces the ideal time and Production loss. KEYWORDS: PTO Shaft, A type pulley, Pulley Ratio, Air inflator, Quick Coupling Mechanism. Copyright 208 International Journal for Modern Trends in Science and Technology All rights reserved. I. INTRODUCTION A Loader is a form of tractor that usually contains a front-mounted square wide shaped bucket connected with the arms to scoop up materials that are loosely bounded. The loader assembly may be a removable attachment or permanently mounted. Often the bucket can be replaced with other devices or tools. The main function of pump in backhoe loader machine is to suck the oil from the tank and circulate the oil throughout the machine in different flow rate. For this paper work, flow rate from the pump is 80 lpm. But hydraulic motor requirement is 30 lpm. So flow control valve is used to control the flow rate of the pump from 80 lpm to 30 lpm. In this flow rate motor starts to rotate at 2500 rpm. Motor is coupled with A type pulley. Mechanical power from the motor is transferred to the compressor through belt drive with same pulley. Pulley ratio is calculated from the diameter of two pulleys. From the ratio, compressor speed has to be set. From the specification, maximum speed of compressor is 700 rpm. So speed has to be set less than 700 rpm. 2 cc hydraulic motor is used to drive.5 hp single cylinder air compressor. So the output power from the compressor is.5 hp. Required air pressure to fill the tyre is 2.5 bar 3.5 8 International Journal for Modern Trends in Science and Technology
bar. So this amount of output power is sufficient to fill the air. A. Proposed System Air inflator is an attachment that is fitted on the front end loader. Whenever the problem arises in the tyre like lints, the attachment is removed from the loader and then it is to be used. This experimental works developed based on the customer requirement. The 3D model of the air inflator attachment of given dimensions was created. The air pressure, flow rate, power from the calculations was checked. The real time model of backhoe loader attachment in vehicle is to be implemented. Figure shows the block diagram for design of hydraulic driven mobile air inflator. Block diagram explains the process involved in this paper work. This explains that how the mechanical and pneumatic operation going to perform in this paper work. Initially hydraulic power from the pump is connected to the flow control valve. This hydraulic power from the flow control valve is connected to the hydraulic motor to actuate the motor. Hydraulic motor and compressor are connected with the belt drive for the power transmission. Then the generated pneumatic energy is passed into the vehicle tyre. Figure 2 shows the block diagram for air inflator attachment of tractor. Flow Control Pump Hydraulic Motor Flow Control Vehicle Tyre Figure Block diagram of Loading Machine II. DESIGN OF PROPOSED SYSTEM The design setup consists of Flow control valve, Hydraulic Motor, Air compressor, A type pulley, Belt drives, and Pressure gauge and Hydraulic hoses. Table describes the list of components. Table List of Mechanical Components S.No. Mechanical Components Quantity Compressor 2 Hydraulic Motor 3 Flow Control 4 Pulley 2 5 Pressure Gauge A. Design Calculation. Pump To find a power of a pump, From quick coupling, (pump) Power = Pressure Flow Power = 40 bar 80 lpm Power = 25.032 hp Consider some losses, Assume power as 20 hp To find a flow rate of Hydraulic motor, Maximum Speed = 3500 rpm Flow = 2 cc 3500 rpm Flow = 42 lpm at maximum speed So, have to decrease the flow rate from 80 lpm to 30 35 lpm At 35 lpm, Speed = 35 lpm / 2 cc = 296.67 rpm At 30 lpm, Speed = 30 lpm / 2 cc = 2500 rpm PTO Shaft Compressor Air Tank Vehicle Tyre 2. Compressor To find the compressor speed, D N = D2 N2 D = 40 mm D2 = 45 mm N = 2500 rpm N2 =? N2 = (2500 40) / 45 N2 = 689.7 rpm Figure 2 Block diagram of Tractor 9 International Journal for Modern Trends in Science and Technology
3. Pulley Ratio To find the pulley ratio of belt drive, N / N2 = 2500/ 689.7 N / N2 = 3.63 (No unit) 4. Motor Power To find the power of hydraulic motor, Torque : 5 N.m at Speed : 2500 rpm Power = 2 3.4 N T / 60 Power = 2 3.4 N T / 60 Power = 3.93 Kw = 5.3 hp 5. Compressor Pressure To find the Pressure of a compressor, Power =Pressure Flow Pressure = Power / Flow Pressure =.5 hp /30 lpm Pressure = 22 bar B. Assembly Model Figure 3 shows the 3-D modeling of hydraulic driven mobile air inflator. This 3-D model was developed in Creo parametric 2.0. This model shows the variant parameters involved in this paper work. Figure 3 3D Model of Loader and Tractor Pulley is of A groove type. So belt used for the pulley is A type belt. At another end, Air compressor is placed in the attachment. From the compressor shaft, 45 mm diameter of pulley is mounted on the compressor shaft. 40 mm & 45 mm pulley are connected with belt drive. Compressor consists of inlet port, outlet port, pressure gauge and other ports. Pressure gauge is used to measure the pressure level inside the air tank. From the outlet port, pneumatic hose is connected to the tyre. III. PRINCIPLE OF OPERATION Initially, Hydraulic pressure from a pump is of 80 lpm that is passed to the flow control valve. Flow control valve decrease the flow from 800 lpm to 30 lpm. Flow control valve is connected to hydraulic motor. 2 cc motor with 30 lpm flow rate starts to rotate at 2500 rpm. Motor coupled with pulley and connected with compressor motor. Pulley ratio have to be calculated from the diameter of two pulleys. 2500 rpm of hydraulic motor speed converted to compressor with 700 rpm speed. In this speed, compressor generates minimum 7 bar pressure which is sufficient to refill the air into the tank. Optimal size & pressure are mentioned in tyre description. 2.5 bar 3.5 bar pressure is need to fill the air in the tyre. This is an easy process to fill the air by using hydraulic energy. No need of electrical power and consume more energy. Figure 4 shows the Compressor attachment of this paper work. This attachment consists of compressor fan, Belt drive between PTO shaft and compressor shaft. This figure shows the overall view of inflator model of tractor. C. Constructional Features Air inflator consists of Flow control valve, Hydraulic motor, Air compressor, Pulley arrangement and Belt drive. Initially, flow rate from machine pump is 80 lpm. That is taken from Quick coupling which is placed behind the bucket. The pump is connected with Flow control valve through hydraulic hoses. Flow rate of 30 lpm is sufficient to rotate the hydraulic motor. 80 lpm from the pump is reduced to 30 lpm by using flow control valve. In that 30 lpm, 2 cc hydraulic motor starts to rotate at 2500 rpm. 0 mm diameter MS shaft is mounted on the motor shaft with the length of 0 cm. 40 mm diameter of pulley is mounted on the motor shaft. Figure 4 Attachment in Vechile Figure 5 shows the Compressor mounting of this paper work. Also this figure consists of pump to suck the atmosphere air and develop compressed 0 International Journal for Modern Trends in Science and Technology
air to the air tank. Pneumatic hose is used to connect the pump outlet and air tank. Figure 7 Flow Control Figure 5 Hose Connection Figure 6 shows the Hydraulic motor which is used in this paper work. This motor is mounted on the front end loader bucket and the hydraulic energy from the quick coupling is connected to the motor to rotate. This motor coupled with a pulley and other end connected to compressor shaft. Figure 8 shows the Motor mounting of this paper work. This motor mounted on front loader machine bucket with proper measurement. Figure 8 Motor with Hoses arrangement Figure 6 Hydraulic Motor Figure 9 shows the Compressor which is used in this project. It consists of inlet port, outlet port and pressure gauge mount. Air tank with a capacity of 30 litre. Figure 7 shows the Flow control valve which is used in this paper work. Flow control valve converts the flow rate of oil from the pump. It consists of inlet and outlet port. 80 lpm flow rate of oil is converted 30 lpm through this flow control valve. Figure 9 Compressor Unit International Journal for Modern Trends in Science and Technology
Content IV. RESULT AND DISCUSSION Table 2 Comparison Table Conventional Method Proposed Method Ideal Time 6 hours hour Production Loss High Low Skill Level Required No Need Radiator Panel Cleaning Not Available Available Table 2 shows the detailed comparison between conventional and proposed method. By considering the above mentioned factors performance of proposed model was studied, This proposed model is better than conventional method. The issues that are arising during the field work can be eliminated by using this proposed method. A. Conclusion This experimental works can be implemented to minimize the human effort. Hydraulic driven air inflator is the testing model that is developed in industry. Testing performance is analyzed and outcome of the experimental works to be good condition. To overcome production loss in field issue, this is the best way to maintain the field work and increases the volume of work. Thus the existing problem can be resolved by this equipment. 5 hours of idle time is reduced to 2 hours. This attachment may be used to clean the lints that blocks in the radiator panel holes. ACKNOWLEDGMENT The authors greatly acknowledge M/s Bull Machines Private Limited, Coimbatore, for providing the support and infrastructure facility to do this experimental work. REFERENCES [] Boetger, R.L., Code Manufacturing, Inc., (984). Instant tire inflator.u.s. Patent 4,489,855. [2] Brown Jr, R.K. and Merrell, R.L., General Motors Corporation, (977).Tire inflator.u.s. Patent 4,054,63. [3] Daoud, A.G. and Anderson, E.B., Ivac Corporation, (994). Flow control valve.u.s. Patent 5,336,74. [4] Goodwin, D., Rose, B., Coleman, N. and Buck, J., Goodwin Daniel U, Rose Barbara A, Coleman Nathan L and Buck John E, (2006). Air compressor. U.S. Patent Application /343,085 [5] Glotin, J., Zefal, (999). Inflator device using a compressed gas cylinder or cartridge. U.S. Patent 5,947,72. [6] Halimi, E.M., Woolenweber, W.E. and Maloof, R.P., Turbodyne Systems, Inc., (2000). Motor-assisted variable geometry turbocharging systems. U.S. Patent RE36,609. [7] Klee, M., Case Co JI, (974). Compact material-handling loader. U.S. Patent 3,828,952. [8] Lee, T.L., Lee Tzal Lin, (990). Supplementary tire inflator. U.S. Patent 4,969,493. [9] Nakayama, S., Watari, Y. and Kurihara, T., Matsushita Electric Works, Ltd., (999). Flow control valve. U.S. Patent 5,865,48. [0] Penn, R.D., Miesel, K.A., Stylos, L., Christopherson, M.A., Nagavarapu, S. and Roline, G.M., Medtronic, Inc., (2004). Device and method to measure and communicate body parameters. U.S. Patent 6,73,976 [] Petrovsky,J. and Roloff, H., Daimler-Benz Aktiengesellschaft, (985). Reciprocating piston air compressor. U.S. Patent 4,498,848. B. Future Scope This experimental work is running in manual mode with the help of operator. In future, this may be replaced and controller fitted with flow control valve to adjust the flow rate to gain power. Second thing is, tubeless tyre has to be fitted in low cost for both construction equipment machine and tractors. So that production loss would be low during puncture. Since it is a mobile air inflator, in future this attachment is fitted with the construction equipment machine. Now this attachment is used for air inflator purpose. In future, it is used as the attachment of jet pump, radiator cleaner and other driven actuators. 2 International Journal for Modern Trends in Science and Technology