AUTOMATIC TIRE INFLATION SYSTEM DESIGN PROJECT

UNIVERSITY OF GONDAR
INSTITUTE OF TECHNOLOGY
DEPARTMENT OF MECHANICAL
ENGINEERING
AMHARA WATTER WORKS CONSTRACTION
ENTERPRISE
Internship report
AUTOMATIC TIRE INFLATION SYSTEM
Team member’s Idno
SELAMAWIT BERHANU 5895/08
MISGANAW ABAT 4740/08
ENDALEW SHIBABAW 07758 /09
Name ofAdvisor; MR Netsanet
Submission date; 05/02/2012ec

AUTOMATIC TIRE INFLATION
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DECLARATION
This report is prepared by a fourth year mechanical engineering students; selamawit berhanu, misganaw
abate, endalew shibabaw that have taken the internship experience in Amhara Water Work Construction
Enterprises(AWWCE) for a period of 4 months from February 06,2019 to June 06,2019 under the
guidance of company supervisors Mr. Misganaw, Mr.anteneh, all mechanics in AWWCE and our mentor
Mr.Nesanet.
To certify that work is original and compiled according to the internship report writing guide line given
by the industry linkage office of the institute.
APROVAL OF OUR SUPERVISOR
Our company supervisor Mr. Misganaw have been beyond a mentor, he always eager to show us what he
know and what he think that might help us in the future, he have been more than insightful in our whole
internship experience at AWWCE.
This project has been fully approved.
APROVAL OF THE ADVISOR
Our adviser Mr.Nesanet have given us a lot of supports and advises in to the making this of this whole
project. This is to certify that the above statement made by the candidate is correct to the best of my
knowledge and belief. This report has been submitted for presentation with my approval.
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Mentor Name Signature Date

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ACKNOWLEDGEMENT
First of all, we would like to express our greatest praise to university of Gondar for everything. In
addition to university of Gondar So many people have a contribution in this project and it would be
impossible to mention them all, but there are persons that we should express our special thanks: that is to
our mentor Mr. Nesanet and our company supervisor Mr.misganaw for their great support and their
insightful advice through the whole internship experience.
We would also like to express our deepest gratitude from the bottom of our heart to our families and
sinour friends for their financial, material, and moral support goes beyond what we can inscribe on
project, it will remain engraved in our heart.
Last but not least, we would like to give a great thanks and respect to AWWCE for providing us this
incredible internship experience, and also we would like to give our special thank the mechanics for their
advice and support.

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ABSTRACT
Since the discovery of tires, amelioration is being done in tires of a vehicle on a regular basis for
its improved life and its role in increasing vehicular safety. As we all know that vehicle is the
most important part of our life, because it helps us in traveling miles in a few minutes. The air
pressure of the tires needs to be maintained at ideal level for better running of vehicle and for its
safety purposes. So this system was introduced keeping in mind the fuel consumption, vehicular
safety and comfort. It maintains the required tire pressure of vehicle, increases fuel efficiency
and reduces tire wear thus increasing their life and reducing the tire replacement time and cost.
Significant aim of introducing this system is to maintain ideal pressure in tires and when the
pressure of tire goes below ideal vale pressure gauge monitors it and the tire is inflated again.
This paper provides a better understanding for researchers and new learners on the working,
advantages and limitations of the “Automatic tire inflation system” used in tires of a vehicle.

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EXECUTIVE SUMMARY
This internship report is written based on the report format given from University of Gondar to
fourth year mechanical engineering students while we were attending in AWWCE Bahir-Dar
branch for last four months. The internship report contains two parts, company report and
project.
The company report contains the first two chapters. The first chapter is about the company
background like: brief history, main products or services, main customers and end users,
organizational structure and the work flow of the company. The second chapter deals with all our
internship experiences like section of working, work tasks we have been executing, engineering
tools methods and techniques, major challenges and problems their proposed solutions. It also
deals about over all benefits we gained from the internship in terms of improving practical skill,
theoretical knowledge, industrial problem solving capability, team playing skills, leadership
skills, understanding about work ethics issues, industrial psychology and related issues,
improving entrepreneurship skills and improving inter personal communication skill.
The project is about automatic tire inflation system and it cover the third chapter which includes
about the internship project which talks about design of automatic tire inflation machine which
contains project title, summary of the project, introduction, working principle, problem
statement, objective, literature review, methodology, force analysis, material selection, design
and analysis, result, discussion, cost analysis, detailed drawing, conclusion and recommendation
of the project.
This project was done based on the problem we and the AWCCE workers faced during
internship period. During this period major problem was there were many run out or wear out
tires and most of the car drivers was coming to shop to change the tires.
So our project was to resolve this problem which is to reduce fuel economy but can also wear out
tire sand reduce vehicle safety through poor handling maintaining correct tire pressure.
This system has three general goals;
 To detect; If the air pressure in tyres has dropped (continuously check the air pressure in
each type)
 To notify; If there is any dropped in the air pressure in any tyre
 To inflate /deflate in cased of overpressure or under pressure the tyre pressure is
maintained inflate the tyre
Finally the fourth chapter deals about general Conclusion and recommendation of the internship
program for a period of four month.

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DECLARATION ................................................................................................................................................i
APROVAL OF OUR SUPERVISOR.....................................................................................................................i
APROVAL OF THE ADVISOR............................................................................................................................i
ACKNOWLEDGEMENT................................................................................................................................... ii
ABSTRACT..................................................................................................................................................... iii
EXECUTIVE SUMMARY................................................................................................................................. iv
CHAPTER ONE ...............................................................................................................................................1
1. COMPANY BACKGROUND AMHARA WATER WORKSCONSTRACTION ENTERPRISE (AWWCE)................1
1.1. History of AWWCE .............................................................................................................................1
1.2. Main products or services of company..............................................................................................2
1.3. Main customers or end users of company ........................................................................................3
1.4. Work flow of the company ................................................................................................................4
CHAPTER TWO ..............................................................................................................................................5
2. INTERNSHIP EXPRIANCE.......................................................................................................................5
2.1. Work of our section in the company .................................................................................................5
2.2. Work tasks executed........................................................................................................................5
2.3. Engineering tools, Methods and Techniques...............................................................................6
2.4. Challenges and Problems we have faced.........................................................................................11
2.5.Measure we have taken....................................................................................................................11
2.6. Over all benefits of the internship...................................................................................................11
Chapter three..............................................................................................................................................15
3. Design of automatic tire inflation system...........................................................................................15
3.1 Introduction ......................................................................................................................................15
3.2COMPONENTS OF INFLATION SYSTEM..............................................................................................17
3.3Material selection ..............................................................................................................................25
3.3.1 Properties of Mild Steel: ............................................................................................................26
3.3.2Martial used for sprocket and chain is carbons tell........................................................................26
3.4SYSTEM WORKING.............................................................................................................................27
3.5ADVANTAGES AND APPLICATION OF THE PROJECT ..............................................................................27
3.5.1 ADVANTAGES:................................................................................................................................27

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3.5.1.1Ability to Provide Proper Tire Pressure....................................................................................27
3.5.1.2 Minimize Negative Visual Aesthetics......................................................................................28
3.5.1.3 Ability to Provide Automatic System ......................................................................................28
3.5.1.4 Low Cost Device ......................................................................................................................28
3.5.2Disadvantage...................................................................................................................................29
3.6Problem statement............................................................................................................................30
3.7objective of project................................................................................................................................31
3.7.1General objective............................................................................................................................31
3.7.2 Specific Objectives .........................................................................................................................31
3.8 SPECIFICATION......................................................................................................................................31
3.9 Methodology.........................................................................................................................................32
3.10LIMITATION..........................................................................................................................................32
3.11 Literature review.................................................................................................................................33
3.12 DETAIL DESIGN OF COMPONENT........................................................................................................34
3.12.1 Calculation for compressor..........................................................................................................34
3.12.2 Chain design.....................................................................................................................................34
3.11.3 Design of sprocket ...........................................................................................................................39
3.12.4Shaft calculations..............................................................................................................................41
3.12.5 Calculation for air valve sizing..........................................................................................................43
3.12.6 Vibration analysis deflection due to resonance...............................................................................43
3.13APPLICATIONS......................................................................................................................................46
3.14 Raw material cost:- .............................................................................................................................47
3.14.1 RAW MATERIAL & STANDARD MATERI........................................................................................47
3.15 RESULT ................................................................................................................................................48
Chapter four................................................................................................................................................49
4 GENERAL CONCLUSIONS AND RECOMMENDATION................................................................................49
4.1CONCLUSION......................................................................................................................................49
4.2Recommendation...............................................................................................................................49
4.3Part and assembly drawing....................................................................................................................50
REFFERANCE................................................................................................................................................57
List of figures

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Figure 1Background of AWWCE....................................................................................................................1
Figure 2. Organizational structures...............................................................................................................4
Figure 3 Work flow in the work shop of AWWCE.........................................................................................4
Figure 4 Work of our section ........................................................................................................................5
Figure 5 Work tasks executed in AWWCE.....................................................................................................6
Figure 6 open end wrenches.........................................................................................................................7
Figure 7 box end wrenches...........................................................................................................................7
Figure 8combination wrenches ....................................................................................................................7
Figure 9adjustable wrenches........................................................................................................................8
Figure 10 snap ring pliers..............................................................................................................................8
Figure 11 pliers..............................................................................................................................................8
Figure 12screw driver ...................................................................................................................................9
Figure 13Feeler gauge...................................................................................................................................9
Figure 14 hammer.........................................................................................................................................9
Figure 15 Air compressor and hydraulic jack..............................................................................................10
Figure 16 hydraulic press and portable crane ............................................................................................10
Figure 17 safety stand and hydraulic jack...................................................................................................11
Figure 18 tires wear ....................................................................................................................................15
Figure 19 survey report...............................................................................................................................16
Figure 20 air compressor ............................................................................................................................18
Figure 21 wheel...........................................................................................................................................19
Figure 22 tire...............................................................................................................................................19
Figure 23 flexible air hose...........................................................................................................................20
Figure 24quick release coupling .................................................................................................................20
Figure 25 rotary joint ..................................................................................................................................21
Figure 26 pressure sensor...........................................................................................................................22
Figure 27 tire pressure due to seal .............................................................................................................23
Figure 28 12v electric motor.......................................................................................................................23
Figure 29 roller chain ..................................................................................................................................24
Figure 30 sprocket.......................................................................................................................................24
Figure 31 .....................................................................................................................................................35
Figure 32 dimension of 06B-1 sprocket......................................................................................................39
Table 3.Figure 33.dimension of sprocket ...................................................................................................40
Figure 34 dimension of 06B sprocket .........................................................................................................40
Figure 35.dimension of shaft ......................................................................................................................41
List of table
Table 1 specification ...................................................................................................................................31
Table 2. RAW MATERIAL & STANDARD MATERIAL.....................................................................................47

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CHAPTER ONE
1. COMPANY BACKGROUND AMHARA WATER WORKSCONSTRACTION
ENTERPRISE (AWWCE)
1.1. History of AWWCE
AWWCE is an enterprise of Road, Water and Farm which was established in early 1988 with the
main objective of providing pure water for the environment. AWWCE is located in west and east
areas of our country namely Bahir-Dar and Combolcha. AWWCE is very developed industry it
start its work with 180 manpower but at the current time it is grown and become a big industry
with 1625 manpower and 1.4 billion capitals. The industry has some charity works and social
activities like support 18 children those have no family and for community policing and schools
support materials and build homes. AWWCE has its own Athletics and Football team which can
make a change for our country sport. The enterprise has three main maintenance shop sites such
as, Bahirdar maintenance site, Combolcha maintenance site and Tan abeles maintenance site.
Weapply on Bahirdar maintenance shop.
Figure 1Background of AWWCE
In west Amhara construction office (Denbecha clean water work project, Temtem, Koga and
Tanabeles irrigation project etc.) In east Amhara construction office (kobo and Sekota irrigation
project, Desietishu cultural project, Ayserawm and Gemera soil dam project) The main activities
in this industry are equipped with appropriate technology, machinery and equipment’s that
enable it to provide efficient services in the following specialized production areas:

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 Road, Water, Farm and maintenance service
 Rig underground water and maintenance
 Heavy duty machinery and generator maintenance
 provides heat treatment, welding and painting services
 Road construction and maintenance service
 Objectives, missions, visions and values of the company Objective
 To satisfy our society in road construction, automotive maintenance service, water
supply and Agriculture.
 To undertake the activities of Engineering that support our country's Economy and
Industry
Mission
 To ensure satisfaction of the society by maintaining and overhauling different models of
Vehicles with better efficiency, quality and at lower cost.
 To increase manufacturing capacity and capability for tools, spare parts and auxiliary
required for overhaul and Assembly activity.
 To be competent and enhance our Nation’s market share from the Global Automotive
&Water source Industry.
Vision
 To be the best factory in east Africa by supplying pure water for the society.
Values
The following are the values that are performed in the company
 The Company works towards the customer satisfaction.
 The Company is team work.
 Punctuality.
 Accepting and respecting all the customers equally.
 The Company treats all employees equally.
1.2. Main products or services of company
The main service of the company
 Road maintenance
 Building construction
 Dam construction
 Irrigation system
The company uses so many types of heavy and light duty vehicles to facilitate their construction,
due to this the company needs large garage shop for maintenance, repairing and service of its

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own vehicles and also have its own manufacturing workshop. In the shop the following service
are performed.
 Brake system
 Engine maintenance
 Suspension system
 Body work
 Welding
 Metal cutting
 Metal bending
 Making internal and external thread on a hollow shaft
 Electrical work
Some types of vehicles that are serviced at shop are
1. Nissan tracker
2. FAW and light vehicles like land cruiser
3. Service buses and mini bus
4. Excavator
5. Crawler dozer
6. Grader
7. Loader
8. Forklift
9. V8
10. Double and single pick ups
1.3. Main customers or end users of company
Since the company services its own vehicles and machinery the main customer is Amhara water
work construction enterprise itself and Ethiopian people and they are contracted by the federal
and regional government in order to perform any task that is related to its objective.

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Figure 2. Organizational structures
1.4. Work flow of the company
Figure 3 Work flow in the work shop of AWWCE
In the AWWCE maintenance workshops there are 4 main parts they are body shop, welding
shop, mechanical shop, and electrical shop. When there is problem to be fixed with a vehicle it is
send to the proper workshop for the maintenance and if there is a vehicle which needs more than
one work shop, by cooperating with each other the shops will repair the vehicle. The body shop:
In this part of the shop the body of the vehicle is repaired extensively .The mechanical shop: is
intended for effecting major repair and tests of engines, vehicles and engineering material, and
for testing power supply units and electric stations. The welding shop: In this part of the shop
different kinds of welding is performed and almost any kind of welding problem can be fixed.
Electrical shop: in this part of the shop all kinds of electrical problems staring from a small
automobile to excavators and dozers

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CHAPTER TWO
2. INTERNSHIP EXPRIANCE
2.1. Work of our section in the company
AWWCE vehicle servicing shop have two main sections which are mechanical shop, includes
technical maintenance of many parts of the vehicle and the body shop is exclusive in body make
over and painting. These two major shops with the help of the electrical section, at this rendering
shop demolished cars got a lot of transformation though inspection and maintenance (engine,
gearbox, differential, steering, lubrication and brake) of the vehicles.
Figure 4 Work of our section
Generally in the company our work section is in heavy duty and automobile vehicles
maintenance and servicing section. Vehicles maintenance and servicing section include the
maintenance and servicing of the following system;
 Engine overhauling
 Power train
 Chassis and Suspension system
 Cooling system
 Brake system
 Lubrication system
 Body repair
2.2. Work tasks executed
We have executed the following tasks:

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 Changing piston and piston rings
 Valve lapping
 Change brake shoe pads
 Repair break air chamber
 Change lubrication oil
 Change broken synchronizer, dog teeth and gears in gear box
 Change the spider of universal joint of propeller shaft connection
 Change broken leaves in leaf spring suspension system
 Change broken dead axles
 Change malfunction fuel filter and fuel pump
 Clean, change air filter
Figure 5 Work tasks executed in AWWCE
2.3. Engineering tools, Methods and Techniques
Engineering tools
The tools that we have been using to perform our tasks in the workshop are those tools that we
use in mechanical engineering workshop. There are two division of tools based on the source of
energy applied on the tools in the maintenance and service of vehicle.
These are; Hand tools
Hand tools are operated by hand. There are many types of hand tool, some of them are:
1. Wrenches
They are used for tightening and loosening of bolts and nuts. There are many types of wrenches.
Some of them are:
 Open-end wrenches: A one-piece wrench with a U-shaped opening that gripstwo
opposite faces of the bolt or nut. This wrench is often double-ended, witha different-
sized opening at each end. The ends are generally oriented at an angle of around 15
degrees to the longitudinal axis of the handle. This allows a greater range of movement
in enclosed spaces by flipping the wrench over.

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Figure 6open end wrenches
 Box end wrenches: A one-piece wrench with an enclosed opening that grips the faces of
the bolt or nut. The recess is generally a six-point or twelve-point opening for use with
nuts or bolt heads with a hexagonal shape
Figure 7 box end wrenches
 Combination wrenches: A double-ended tool with one end being like an open-end
wrench or open-ended spanner, and the other end being like a box-end wrench or ring
spanner. Both ends generally fit the same size of bolt.
Figure 8combination wrenches
 Adjustable wrenches: The adjustable end wrench differs from the monkeywrench in
that the gripping faces of the jaws are displaced to a (typically) 15 degree angle relative
to the tool's handle, a design feature that facilitates the wrench's use in close quarters.

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Figure 9adjustable wrenches
2. Snap ring pliers
• Two types - external snap rings and internal snap rings
• Internal snap rings require contracting jaws
•external snap rings require expanding jaws
Figure 10 snap ring pliers
3. Pliers (pinesaps)
They are used to grip different size of materials. Used for holding, gripping, cutting, and
crimping. Usually forged from hardened steel and then machined.
Figure 11 pliers

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4. Screw driver
They are used to drive or turn screws. It can be flat or Philips head. A screwdriver is a tool,
manual or powered, for turning (driving or removing) screws. A typical simple screwdriver has a
handle and a shaft, and a tip that the user inserts into the screw head to turn it. The shaft is
usually made of tough steel to resist bending or twisting.
Figure 12screw driver
5. Feeler gauge
It used to measure the gap or clearance between two components. Used for: Piston ring gap,
Piston ring side clearance, Connecting rod side clearance Warp page, measuring crankshaft end
float.
Figure 13Feeler gauge
6. Hammers
Hammers are used to force objects together or apart. The shape of the back part of the hammer
head (called the peen) usually determines the name.
Figure 14hammer

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Power tools
Power tools which operate by electric, compressed air or hydraulic pressure. There are many
types of power tools. Some of them are:
1. Air compressor:
Is driven by an electric motor and used to compress air for different purpose. Example to
clean dust particles from different body parts of an automotive.
2. Hydraulic jack: It used to carries the body of cars during service.
Figure 15Air compressor and hydraulic jack
3. Hydraulic presses
Hydraulic presses are hand- operated hydraulic cylinders mounted to a stand, designed to press
bearings on or off of shafts and other components.
4. Portable crane
A portable crane is used to remove and install engines and other heavy components. Most use a
hand-operated hydraulic cylinder to raise and lower a boom, equipped with a nylon strap or steel
chain.
Figure 16hydraulic press and portable crane

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5. Hydraulic jack and Safety stand
They are used for support or carry the vehicle after lifted by a hydraulic jack. They are widely
used in the shop and are very essential for lifting up.
Figure 17 safety stand and hydraulic jack
2.4. Challenges and Problems we have faced
Behind every success, there is /are obstacles or challenges. Among the challenges We have been
faced, some of them are:
 The mechanics can’t relate the theory part with the practical work
 Lack of team work
 Lack of safety materials
 Absence of measuring devices
 Shortage of tools and equipment’s
 The working place is so rough and dusty
2.5.Measure we have taken
Measures taken to overcome the challenges:
We try to discuss each other with the students that came from other universities to relate the
theoretical part with practical
 Through time it is obvious that relations are made between workers and us, because we
discuss and helping each other for problem solving issues.
 We suggest the company to fulfill the safety materials for the future, measuring and tools
and equipment’s.
 As much as possible, we try to use materials in the place where it is suitable for it. Finally
we try to manufacture our project which is automatic tire inflation and we try to minimize
one of these absences machines.
2.6. Over all benefits of the internship
In terms of improving practical skills:

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From this internship program, we have got a good chance to improve our practical skill highly.
We can develop our skill by participating ourselves into different parts as we had learned
theoretically in our department course among them.
Designing new project-by taking problem of the company under consideration we havedesigned
to solve the main problem of the company.
Inspection- daily before work started the first thing is checking, such as oil, fuel on each
machinery and truck, checked & inspected.
Machine maintenance:-There are activities which are maintain daily, weekly monthly & yearly
according to the maintenance plan. The types of maintenance we used to practice are:
a) Lubrication-daily before the machinery start work, parts such as, water tubes, filters, Crank
shaft are checked they can lubricate correctly.
b) Repair – after inspection if there is wear part repair it & make it ready to function, such as
liner, fly wheel, wear bolt & othersc) Replacement- parts which are highly damaged such as
gasket, seal and also others are replaced using new spare part to make it ready for use again.
In terms of upgrading theoretical knowledge:
In terms of upgrading our theoretical knowledge we gained detail & clear knowledge about how
can we design and modified different types of machinery, how can manufacture machinery parts
in machine shop, classifying them into daily, weekly, monthly, and yearly. And also how can
order spare part list using their item code by referring manual and using inventory list for each
part according to maintenance plan.
In terms of improving our team playing skill
During the internship time we were working with students which came from another universities
which helped us to discuss problems we faced in the company to adapt ourselves to the new
environment fast. Also while we observe different section of the company we discuss what we
had seen in the section relating it with what we have learnt before and we discuss on new ideas
which may be raised between us since each of us may have different ideas.
Understanding on what we observe, also after we identified problems and prepare our project
personally we kept working and helping each other. We also gain best team playing skill from
the workers of the company which will help us for the coming work time.
In terms of improving our leadership skills
There are good qualities that one leader must have in order to work successfully and must be an
example for other workers and allowing the growth and profit of the company to go high and

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creating good working condition for workers. This skill helps us to know and develop qualities
of a good leader which will be one of our duties in the future.
We have also the chance that we act as a leader in the office the garage case team which gives us
plenty of leader ship skill that will make us not new for the near future.
In terms of understanding work ethic issues, industrial psychology and relate
issues:
Work ethics is a set of values based on hard work and diligence. It is also a belief in the moral
benefit of work and its ability to enhance character.
From this program we can help how to improve work related issue before we meet such an
organization or when we contact our self in such social network environment, some of them
includes punctuality, attendance, conducting quality work, respect for fellow workers, honesty,
and showing initiative. A work ethic include being reliable, have initiative, or pursuing new
skills.
And also we gained a good work ethics for better positions, more responsibility & ultimately
promotion (placed in positions of a greater responsibility). These all are teach me a lot for the
future work life of our self.
Characteristics That We Gained Generally Includes Being:
 Strong work ethics – learning the most efficient way to complete tasks & finding ways to
save while completing daily assignments.
 Dependable & responsible – come on time, responsible for the actions.
 Adaptability- adapting to the personality & work habits of coworkers&supervisors being
open to change.
 Possessing a positive attitude – to get the job done in a responsible period of time,
motivates others to do the same with in challenges.
 Honesty and integrity –is the responsibility of each person to use their own individual
sense of moral & ethical behavior when working within the scope of their job e &
improvement to complete work in more efficient.
 Our internship practice also helped us to know industry working culture, obeying work
time, respecting co-workers, understanding office rules and some company safety rules.
In terms of entrepreneurship skills
During our internship time we have gained the skill of entrepreneurship that means we proposed
some business areas which will be profitable for the future as well as the following
entrepreneurship skills;
 High need for achievement

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 Willingness to take risks
 A need to exercise leadership
 Self confidence
 Creativity Combine theoretical part we learn in the campus with practical part we get in
the working area.
 Prepare us for fulfilling life, meaningful work, and responsible citizenship.
 Gain valuable work experience and exposure to the workplace.
 Preparing us to be productive engineers, as well as thinkers, doers and leaders.
 Provide us the opportunity to develop attitudes conductive interpersonal relationships.
In terms improving interpersonal communication skill
As we understand from internship we have got good interpersonal communication skill. For team
work interpersonal communication has great value to do qualified work. We also learned some
other Italian name that the mechanics use for maintenance equipment.

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Chapter three
3. Design of automatic tire inflation system
3.1 Introduction
The “Automatic tire inflation system” is an automatic device which is widely used in
automobile works. The manual work increases the effort of the man power (operator) during
the air checking in vehicles. The Air Maintenance Technology system developed through
this project replenishes lost air and maintains optimal tire cavity pressure whenever the tire
is rolling in service, thus improving overall fuel economy by reducing the tire’s rolling
resistance. Automation can be achieved through computers, hydraulics, pneumatics,
robotics, etc., of these sources, pneumatics form an attractive medium for low cost
automation.
According to a study approximately 80%of the vehicles on the road are driven with one and
more tyre under inflated. Tyrelooses air during normal driving (especially after hitting pot
holes or curbs) and seasonal changes in temperature.
Figure 18 tires wear
The vehicle can also lose one or two psi each month in winter and even more in the summer
and you can’t feel if they are properly inflated just by looking at them. This is simply which
is installed on the vehicle that enables the operator to adjust the inflation pressure of
individual tyre of vehicle.
Over a period of 2013 a trial was conducted involving two cement tankers in NSW.
Australia for the first six weeks this system was turned on in both tankers and for another
six weeks this system was turned off and graphs was prepared which shows that trucks with
this system was in good condition like average vehicle time spent using power take off

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average emission and fuel combustion. We also carried out a survey off different people and
asked them when they inspect their tyre pressure the report is as follows
5.40% - 6month
8.10% - bi-month
24.32% - monthly
13.51% - 5-10days
43.24% - weekly
5.40% -3-5days
Figure 19 survey report
The problem they were facing was tire wear, time and effort to check as well as fill the
correct air pressure. Also some unprofessional guys do not fill the correct pressure in the
tyre which leads to over inflation or under inflation on tire. To overcome all thus our system
is the best suitable system also in summer days when we drive the temperature of tyre
increase rapidly consequently .the heated air inside the tyres expands and its pressure rises
quickly which can lead to a tyre blow out with disastrous consequence so there for to
maintain the correct tyre pressure in any weather condition we must enabled this system.
To the required level if there is drop in the tyre pressure and there has to be an air supply as
well as check wall that opens only when needed. It consists of compressor which supplies
air and air tank is used to store air at constant pressure.

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This pressurize air can be filled in totyres through flexible ducting with the help of rotary bearing
the pressure condition are achieved by pressure gauges.
The mode of transportation is one of the most important criterions these days the vehicles safety
is thus essential. Accidents are also increasing at a quick pace. There are several factors which
causes these accidents. The improper inflation of tyres is one among them. Tyres lose air through
normal driving (especially after hitting and seasonal pot holes or curbs) permeation and seasonal
changes in temperature. When tyres are under inflated tyres getting damaged quickly due to
overheating as compared to properly inflated tyres .The under inflation also causes a small
depreciation in the mileages as well.
Above all the vehicles running with under inflated tyres can cause accidents.
Thus to rectify all these defects we are using inflating systems the pressure monitoring in such
systems helps in monitoring the tyre pressure constantly.
Under inflated tyres increase rolling resistance which cannot only reduce fuel economy but can
also wear out tyre sand reduce vehicle safety through poor handling maintaining correct tyre
pressure and monitoring for un even tyre wear (which can be caused by poor wheel
alignment)can help to ensure optimum vehicle performance.
3.2COMPONENTS OF INFLATION SYSTEM
These are component and specification used for the manufacture of the project
a) Air compressor
b) Wheel
c) Tire
d) Flexible air hose
e) Quick release coupling
f) Axle
g) Rotary joint
h) Pressure switch
i) Motor
j) sprocket
k) chain
l) solenoid valve
m) pressure relief valve
A) AIRCOMPRESSOR:
An air compressor is advice that convert 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 force more and more air into a storage tank increasing the
pressure.

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When thank pressure reaches its upper limit the air compressor shut 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 thank pressure reach its lower limit the air compressor turn on
again and re pressurized the tank .the system uses compressor to get the air from atmosphere
and to compress it to a required pressure. A compressor of heavy truck has being used in our
system. It is perfect for car, bikes and inflators.
Figure 20 air compressor
B) WHEEL
It is circular component that is intended to rotate on an axle bearing.Tire are mounted
onto wheel that most often have integral rims on their outer edge to hold the tire.
Automotive wheel are typically made from pressed and welded steel or a composite of
light Wight metal alloys s0000uch as aluminum or magnesium these alloy wheel may be
either cast or forged .the mounted tire and wheel assembly is then bolted to the vehicles
hub. A decorative hub cup and trim ring may be placed over the wheel.

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Figure 21 wheel
C) TYRE
A tire is ring shaped vehicle component that covers the wheels rim to project it and
enable better vehicle performance. Most tires such as those for automobiles and bicycles
provide traction between the vehicle and the road while providing a flexible cushion that
absorbs shock.
The material of modern pneumatic tires is synthetic rubber natural rubber fabric and wire
along with carbon black and other chemical compound. They consist of a tread and a
body. The tread provide traction while the body provide containment for quality of
compressed air. Before rubber was developed the first version of tire were simply band of
that fitted around wooden wheel to prevent wear and tear. Early rubber tire were solid
(not pneumatic). Today the majority of tires is pneumatic inflatable structure, comprising
a doughnut shaped body of cord and wires encased in rubber and generally filled with
compressed air to form an inflatable cushion pneumatic tire are used on many types of
vehicle, including cars, bicycles, motorcycles, truck, heavy equipment and aircraft. Metal
tires are still used on locomotive and railcars, and solid rubber (or other polymer) tire are
still used in various nonautomotive application such as some caster, cart, lawnmowers
and wheel barrow.
Figure 22 tire
D) FLEXIBLE AIR HOSE
It is kids of hollow tube which is used to transport air from the compressor to the tyre and it
is flexible due to which it can easily transport.

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Figure 23 flexible air hose
E) QUICK RELEASE COUPLING
A quick connect fitting also called a quick disconnect or quick release coupling is a
coupling used to provide a fast, make-or-break connection of fluid transfer lines.
Operated by hand quick connect fittings replace threaded or flanged connection which
require wrenches. When equipped with self-sealing valve, quick connect fitting will upon
disconnection, automatically contain any fluid in the line.
Figure 24quick release coupling
F) AXLE
An axle is central shaft for a rotating wheel or gear. On wheeled vehicle the axle may be
fixed to the wheel rotating with them or fixed to the vehicle with the wheel rotating around

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the axle in the case, bearing or bushing are provided at the mounting point where the axle is
supported. In the latter case, a bearing or bushing sits inside a central hole in the wheel to
allow the wheel or gear to rotate around the axle sometimes especially on bicycle the latter
type axle is referred to as a spindle.
G) ROTARY JOINT
A rotary union or swivel joint is mechanism used to transfer fluid (under pressure or vacuum )
from a stationary inlet to a rotating outlet , preserving and isolating the fluid connection also
referred to as rotary joint : rotary union are engineered to endure a large of temperature and
pressure for a variety of condition and environment. In addition rotary union may integrate
multiple independent flow connection (passages) and handle different types of media
simultaneously. Rotor unions typically function by connecting to an input and securing onto
another mechanism by allowing a moving connection to be preserved. Rotary unions are utilized
in a variety of rotary application from compact unions for the semiconductor industry to large
ragged-duty fluid swivels for industrial variety of application. Additionally, material, sealing
technology and bearing types can be incorporated.
Figure 25rotary joint
H) Pressure sensor
It is a device which is used to sense the pressure andtransmit the signal (onoff) to the
solenoid valve depending upon the current pressure.A pressure sensor is a form of switch that
closes an electrical contact when a certain set fluid pressure has been reached on its input.
The sensor may be designed to makecontact either on pressure rise or on pressure fall
pressure sensor are widely used in industry to automatically supervise and control system
that use pressurized fluids. The most important task in this system is to detect the actual tire
pressure and measure how much is exactly needed to be supplied so that the tires are re-
inflated, so the pressure gauge and sensors are the most important devices.

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Figure 26 pressure sensor
The sensor detects the minimum and maximum pressure level. It will be in ON position
whenever the pressure level goes below the boundary level of Poptimum-min. (minimum
optimum pressure) and consequently will be turned OFF when the pressure level goes above
Poptimum-max.(maximum optimum pressure).The pressure sensor we used in project is
PQ7834Reading shown by gauge simple hence it is very accurate and easy to read for the
user. The pressure gauges are classified according to the precession (least accurate is grade
D–5% error and most accurate is grade 4A -0.1% error). A diagram (Figure 3.10) illustrates
the opening of seals due to pressure and it remains open until pressure is relieved.
Type-PQ7834
MEASURING pressure-1-10bar or14.5-145psi
Permissible over pressure-20bar or290 psi
Bursting pressure-30bar or 435 psi

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Figure 27 tire pressure due to seal
I) Electric motor
Direct current electrical energy in to mechanical energy. The most common types rely on the
ADC motor is any of class rotary electric machines that converts forces produced by magnetic
fields. Nearly all types of DC motors have some internal mechanism either electromechanical or
electronic to periodically change the direction of current flow in part of motor. We manufacture
12 Volt DC Motors based on detailed discussions with the customer of the specifications for
each application. There is no additional cost involved for the motor design, but the performance
is greatly enhanced over that of an “off-the-shelf” motor.
We produce motors from fractional horsepower up to 2 HP. Our motors range from 3.25” up to
6” in diameter. Our 12 Volt Motor is capable of speeds up to 5,000 RPM as required. A MET 12
Volt DC Motor is a low-voltage motor that is prepared custom to your company’s specific needs.
We manufacture DC motors with speed control compatibility, which provide you with variable
speeds. All of our Electric Motors have bi-directional and reversible capabilities. They are all of
ball bearing construction and have heavy duty finishes. Special couplings and mountings are
easy for us to provide. We supply 12VDC Motors to many Original Equipment Manufacturers
(OEMs) for a wide variety of products.
Figure 28 12v electric motor

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J.Chain Drive
Chain drive is a way of transmitting mechanical power from one place to another. It is often used
to convey power to the wheels of a vehicle, particularly bicycles and motorcycles. It is also used
in a wide variety of machines besides vehicles.
Figure 29 roller chain
K.Sprocket
A sprocket or sprocket-wheel is a profiled wheel with teeth, cogs, or even sprockets that mesh
with a chain, track or other perforated or indented material. Sprockets are used in bicycles,
motorcycles, cars, tracked vehicles, and other machinery either to transmit rotary motion
between two shafts where gears are unsuitable or to impart linear motion to a track, tape etc.
Figure 30 sprocket
L, solenoid valve

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It is an electromechanical controlled device which is used to allow or restricted the flow of air to
pass through them from the compressor. It is attached between the compressor and the Flexible
air hose. The coilsolenoid casing which is hollow and has a metallic finish in outer, in the
hollow part the coil winding is present, which is energized and de-energized by the lead wire.
The plunger is present at the centre of the casing with the calibrated spring, which is above the
plunger. 3/2 solenoid valve is used to pass compressed air into tyre as well as into atmosphere
form compressor unit. 3/2 Way Direct Acting solenoid valves utilizes the armature movement as
the direct means to the Open/Close the inlet or exhaust ports of the solenoid valve. 3/2 way
normally open solenoid valve inlet port 1 is open to outlet port 2 with exhaust port 3 closed,
when powered or energized inlet port 1 is closed and outlet port 2 is allowed to vent through
exhaust port 3. However in some instances a3/2 way normally open solenoid valve configuration
will use port 3 as the inlet port and port 2 as outlet thus makes port 1 the exhaust port. This
configuration is quite common and offers a reduced cost way of obtaining a 3/2 way normally
open functions. 3/2 way universal solenoid valve has the added advantage of being able to accept
inlet pressure at any port and control flow in any direction. The functionality of this valve works
on the same principles as normally closed or open versions but does not have the limitations of
flow directly associated with other designs. This is very beneficial as the inlet, outlet and exhaust
ports can be piped up in any configuration to suit the application, so can be used as normally
closed, open or as a diverting valve.
M, PRESSURE RELIF VALVE
Tire relief valves each tire must be equipped with a relief valve to prevent it to burst in case of
failure of the system (which is not supposed to happen since the SVs used to supply the tires are
normally closed).. Their opening pressure depends on the type of tire. The one considered from
the beginning, the P 275/80 R22.5, can bear pressures up to 8.2 bars so the opening pressureof
the relief valve should be 8.2 bars.
Tire relief valve
– Port connection inlet: G1⁄4
– Opening pressure: 15 bars
3.3Material selection
The selection of the materials depends upon the various types of stresses that are set up during
operation. The material selected should with stand it. Another criterion for selection of metal
depends upon the type of load because a machine part resist load more easily than a live load and
live load more easily than a shock load.
Selection of the material depends upon factor of safety, which in turn depends upon the
following factors.

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1. Reliabilities of properties
2. Reliability of applied load
3. The certainty as to exact mode of failure
4. The extent of simplifying assumptions
5. The extent of localized
6. The extent of initial stresses set up during manufacturing
7. The extent loss of life if failure occurs
8. The extent of loss of property if failure occurs
Materials selected in machine; Base plate, motor support, sleeve and shaft
Material used-Mild steel
Reasons:
Mild steel is readily available in market
 It is economical to use
 It is available in standard sizes
 It has good mechanical properties i.e. it is easily machine able
 It has moderate factor of safety, because factor of safety results in unnecessary wastage
of material and heavy selection. Low factor of safety results in unnecessary risk of failure
 It has high tensile strength
 Low co-efficient of thermal expansion
3.3.1 Properties of Mild Steel:
M.S. has carbon content from 0.15% to 0.30%. They are easily wieldable thus can be hardened
only. They are similar to wrought iron in properties.Both ultimate tensile and compressive
strength of these steel increases with increasing carbon content. They can be easily gas welded or
electric or arc welded. With increase in the carbon percentage weld ability decreases.
 Mild steel serve the purpose and was hence was selected because of the above purpose
3.3.2Martial used for sprocket and chain is carbons tell
Properties of carbon steel
Carbon steels are iron-carbon alloys containing up to 2.06% of carbon, up to 1.65% of
manganese, up to 0.5% of silicon and sulfur and phosphorus as impurities. Carbon content in
carbon steel determines its strength and ductility.The higher carbon content, the higher steel
strength and the lower its ductility. According to the steels classification there are following
groups of carbon steels:
Low carbon steels (C < 0.25%)
Medium carbon steels (C =0.25% to 0.55%)
High carbon steels (C > 0.55%)
Tool carbon steels (C>0.8%)
Properties: high strength, hardness and wear resistance, moderate ductility.

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Applications: rolling mills, rope wire, screw drivers, hammers, sprocket, chain,
wrenches, band saws.
 We selected high carbon steel
3.4SYSTEM WORKING
In this system, compressor is connected to the wheel with the help of hoses through a rotary
joint. Pressure sensor and control circuit are attached between wheel and compressor. Two limits
(upper limit and lower limit i.e. 20psi and 30 psi individually) are set in the control circuit for
automatic start and stop of compressor. Compressor works on 12V DC supply .A non-return
valve is placed between pressure sensor and compressor, so that the air flow must be
unidirectional from compressor to tire.
When the pressure reduces below the lower limit in the tyre during its rotation, pressure sensor
senses the air drop and starts the compressor and solenoid valve automatically for filling of air
into the tyre with the help of control circuit. As soon as the pressure crosses the set upper limit
(30psi), compressor stops working with the help of pressure sensor and control circuit. In this
way, a proper required tire pressure is maintained.
3.5ADVANTAGES AND APPLICATION OF THE PROJECT
3.5.1 ADVANTAGES:
3.5.1.1Ability to Provide Proper Tire Pressure
The ideal functional objective of our design is its capability to adjust the pressures in all four
tires of a Passenger vehicle to obtain the proper pressure for varying road/driving conditions.
Specifically, it is desired that:
• Cold tire pressure is maintained during vehicle use to account for slow leaks andFluctuating tire
temperatures
• As vehicle speed increases, tyre pressures increases
• As vehicle speed decreases, tyre pressures decreases
• As vehicle load increases, tyre pressures increase
• As vehicle load decreases, tyre pressures decrease
Based on more detailed research on the components necessary for the system, it was discovered
that a specialized rotary joint must be designed to support this process. This design consideration
required additional product development time that was not originally anticipated. Therefore, the
ideal functional objectives have been modified to account for this design requirement.
Specifically, the new objectives require that:

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• Cold tire pressure is maintained by ensuring that the rotary joint-shaft system does not fail
structurally.
• Cold tire pressure is maintained by ensuring that the rotary-joint shaft system does not leak
excessively
• Cold tire pressure is maintained by ensuring that the entire system (compressor, Air tubes,
rotary joint, etc.) can provide sufficient flow rate. Because of the detailed level of explanation
required for these items, these objectives are described numerically in the Engineering Analysis
and Optimization section of this document.
3.5.1.2 Minimize Negative Visual Aesthetics
Another design objective is to ensure that the product will not have a negative effect on current
vehicle Aesthetics. All components should be located as inconspicuously as possible and should
only be seen when servicing the unit. However, in the case of the rotary joints, which may still
be visible through the Wheel rims, an attempt must be made to minimize its visibility around the
brake disks. Specifically, it is desired that Where Visible is the visible area of the rotary joint and
Disk is the visible area of the brake disk.
3.5.1.3 Ability to Provide Automatic System
A third objective is to provide all of the said benefits to the user through an automatic system,
thus minimizing user intervention. Specifically, it is desired that the system automatically
increase or decrease the tire pressures for the given road conditions. However, since this
objective is closely linked with the ideal objectives in maintaining the proper tire pressure, and
thus unattainable due to time constraints, this objective will not be pursued.
3.5.1.4 Low Cost Device
For both the customer (OEM) and end user (vehicle owner), it is imperative to keep the price of
the device as low as possible. Considering the potential benefits and cost savings that this design
has to offer and the prices of optional equipment for passenger vehicles with similar complexity,
the target price range for this device has been identified as. This is the price for both the OEM
and vehicle owner, assuming that the OEM does not mark up the price. In addition, this price
range should be able to support the costs of components of the system, manufacturing, and any
necessary installation.
In addition important positive point of this system as explained below;
1. The main advantage is that you don’t require checking tire pressure daily it saves the time
of air filling.
2. This will reduce the tire wear because of uniform pressure in the tires.
3. The coast of the system is optimized but increase safety comfort and efficiency.
4. The weight of the system is very less so one can use in car, buses etc.
5. With this you don’t haveto stop in that area which is not safe for you when a tire gets
punctured.
6. Reduce tire blowout since tires remain at the proper inflation level at all time.

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7. Reduce maintenance and efficiency.
8. Reduce human efforts.
9. Increase the vehicle efficiency.
10. Increase the life span of tire
11. Avoid accident and fatality.
3.5.2Disadvantage
Automatic tire inflation systems rarely have any disadvantage but there are quite a few:
1. As the rotary joint continuously moves its life is limited it needs to be replaced after sometime
time but with proper maintenance it can work for longer duration of time.
2. Seals must be replaced regularly for optimum results.
3. Pipes and tubes must be inspected from time to time.

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3.6Problem statement
As we are aware that maintenance of correct tyre pressure is extremely important for the
enhancement of tyre life, due to drop in the pressure the tyre goes underinflated and reduce fuel
economy quickest tyre wear, not properly inflation system which will properly inflate the tyre all
the times.

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3.7objective of project
3.7.1General objective
The major objective of this design project is to design automatic tire inflation system.The overall
goal of our design project is to develop a product that will decrease tire wear while improving
fuel economy, performance and safety of a passenger vehicle through dynamically-adjustable tire
pressures. However, there are several key objectives that the team has targeted our design to
meet, and these objectives include both design characteristics and business objectives.
.
3.7.2 Specific Objectives
The specific objective of this project is to design the components of automatic tire inflation
system the, such as designing components needed for systemand the drawing the assembly
drawing of this components.
3.8 SPECIFICATION
The specification and material used for manufacturing of different components are as follows.
Table 1 specification
Si no Description Specification
1 Electric motor 12 DC V
2 Compressor 120 psi(8.25bar)12v DC
3 Rotary joint Size=1/2 pressure=10Kg/cm2
4 Pressure sensor Pressure ranges=0-100psi
5 Bearing Roller bearing, carbon steel
6 Chain sprocket No. of teeth=18, carbon steel
7 Shaft Carbon steel
8 Frame 100*210*100, mild steel
9 Wheel Auto-rickshaw
10 Chain 06B roller chain, carbon steel
11 Solenoid valve 3/2way universal SV
12 Pressure relief valve measuringpressure-1-10bar
13 BYATTER 12V

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3.9 Methodology
The project stated with decision with the project guide about design. This decision covering
project over view and throw out opinion related about title and instruct to proposed a certain
design and concept before go up to next step .then start to make and decide the best idea about
the title. Before that literature review and research about title is the important point to get the
best idea. Then study and make a lot of investigation and research about conventional air filing
system process to fabricate and material. These tasks have been done through study on the
internet, books and other information
After gather and collect all related information’s and obtain new idea and knowledge about title
the project would continue with the design process In this stage the knowledge and idea should
throw out in sketching process. after several design sketched the best design would be choose
among previous design so that we could carry on designing process then the selected design in
order to for analysis proceeds. After that material preparation which is has been confirm initially
.purpose of this process is to determine the suitable follow the product and design
requirement..Here this process is important because the material would determine whether our
product in away to failure or otherwise .analysis stage has been implemented. The evaluation is
by considering the strength, portable, durability, safety and others. After all process above done
on schedule without any problem such as product defect all material for report writing is
gathered.
Then we go to posses of design calculation analysis then we have putted results and conclude. to
design each and every component we go through a lot of researches on internet.aft this we we put
all our analysis to solid work to show the part drawing and 3d drawings.
3.10LIMITATION
Automatic tire inflation systems rarely some disadvantage but there are quite a few As the rotary
joint continuously moves its life is limited it needs to be replaced after sometime time but with
proper maintenance it can work for longer duration of time.another limitation is battery may lose
power due to this system

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3.11 Literature review
CTIS (central tire inflation system) was first used in production on the America DUKW
amphibious truck which was introduced in 1942
The Czech heavy military 8x8truck tarta T813s central inflation and deflation system was
designed to maintain pressure even after multiple bullet punctures. Militarytarta trucks are
equipped with CTIS as a standard.
From 1984 GM OFFERED CTIS for the Chevrolet blazer and pickups. Several trucks used by
the U.S military also have CTIS (e.g. the HMMWV and its civilian counterpart the hummer HI.
the feature is also common in soviet and Russian military trucks.
P.Omprakash, T.Senthil Kumar, “M.A.R.S -
Mechanized Air Refilling System”: The aim of this study is to design and fabricate a system
which reduces human labor and time by eliminating the condition of driver to go to a gas station
or he has to attach a pump manually as physical connection of tyre and pump consumes more
time. Secondly, tyre must not be under inflated nor over inflated i.e. pressure should be in
Central Tyre Air Inflation System 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 take
off, average vehicle GHG emissions, average vehicle fuel consumption across the trial period.

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3.12 DETAIL DESIGN OF COMPONENT
3.12.1 Calculation for compressor
Calculation for compressor selection
For tyre pressure of 120 psi
Where 1psi=0.06895bar
There for
120psi=120*0.06895bar
=8.274bar=8.2bar (approx.)
There for we are selecting 12v DC…...bar compressor for tyre pressure of 105 psi to 120psi.
The system uses compressor to get the air from atmosphere and to compress it to a required
pressure. A 12V DC compressor has been used in our system. It is perfect for cars, bikes and
inflators. It operates from the cigarette lighter socket of a DC-12V. Proper design has been set up
for fixing hose and cord. It is ideal for inflating all vehicle tires and other high-pressure inflators.
The following table shows the specification of our portable compressor.
3.12.2 Chain design
Summing Up the Process of Chain Length Calculation
Calculating chain length is an iterative design process. The procedure for designing and
determining the center-to-center distances and chain lengths for a given chain drive system is as
follows;
1. Determine the sprocket and chain pitch
2. Determine the necessary drive ratio and the number of teeth for each sprocket.
3. Determine the required center-to-center distance for a given design.
4. Calculate the chain length for the required center-to-center distance.
5. Round off the chain length to nearest (Longer) even number of pitches
6. Using the computed chain length (Even number of pitches), recalculate the center-to-center
distance.

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Calculating the Overall Dimensions of a Chain and Sprocket Drive
It is often necessary to integrate chain and sprocket drives systems into mechanisms where space
is at a premium. Small form factors and necessity to reduce weight demand close fitting
tolerances. Designers must be able to accurately calculate the specific and overall dimensions of
the drive systems they create in order to ensure that they will integrate with an existing
mechanism without interference. In order to generate a successful design it is necessary to
calculate the following:
Minimum Center Distance
The arc of the chain engagement on the smallest sprocket should not be less than 120 degrees.
For drive ratios greater than 3:1, the center distance of the sprockets should be equal to or
greater than the difference of the 2 sprocket diameters. This will ensure 120 degrees of chain
wrap around the smaller sprocket.
Maximum Center Distances
The American Chain Association suggests that center distances between sprockets should not
exceed 80 Pitch Units ( For unsupported chain drives). Excessively long center distances create
centenary tensions that act to increase chain wear and result in unnecessary chain vibration.
Consider supporting the chain on guides or rollers where long center distances are required.
Chain -06 B Pitch (P) = ¼” = 6.35
PR = Pitch Diameter x 0.5
Drive Sprocket (n) = 10 Teeth
Driven Sprocket (N) = 30 Teeth
Center Distance (C) = 6”/0.250 = 24 (expressed in pitch units
The chain length = 2 (Tangent line length BE + arc ME + arc BK)
Figure 31 chain lengt dimensions

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Procedure
1. Calculate the pitch circle radius for the drive sprocket.
Procedure
1. Calculate the pitch circle radius for the driven sprocket.
AB=
* + * + [ ]
2. Calculate the pitch circle radius for the driven sprocket.
DE=
* + * + [ ]
3. Calculate the length of side DF
a. Line AF is parallel to line BE and perpendicular to AB and DE
b. Line BE is tangent to circles K and M
c. Line DF = DE-AB
d. Line DF =11.37-4.32–= 7.05
4. Calculate angle a.
a. Triangle AFD is a right triangle
b. Use the math mnemonic trigonometricto find the sine of angle a.
………we substitute
=0.293
To find the measure of angle a with a sine of 0.0083we take the inverse
sin-1<a=
5. Calculate the length of the chain between the pitch circle tangent points, BE. Since angle a =
then we can use a calculator to find the cosine of 17.03 = 0.956
Use the math mnemonic trigonometric and the cosine of angle a to find BE
= we can rewrite this algebraic statement substituting the values we already
know.

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Cosine a= =0.956= expression equal to AF = 0.956 x 152.4=145.69
To express this answer in pitch units we divide the length in inches by the pitch.
=22.94
Since AF = BE then BE =22.94pitch units.
Here are the relationships we determined in the exercise above.
BE = AF = AD cosine a = C cosine a =22.94 pitch units
6. Find the pitch lengths of chain wrapped around each of the sprockets.
Note: Each tooth on the sprocket represents a pitch unit. Therefore, if we calculate the arc
lengths of chain wrapped around the sprocket in terms of teeth, we will have the arc lengths in
pitch units and it will be unnecessary to convert inches to pitch units.
Half the chain wrapped around the large sprocket is represented by arc ME. Measured in pitch
units (teeth) we find;
ME=MH+HE=
Half the chain wrapped around the small sprocket is computed in a similar way, except, the arc
length of angle a is subtracted from the 90 degree arc KG. Note that the chain does not wrap the
small sprocket in as many degrees of arc as it does the large sprocket. Prudent chain drive
designs dictate that the angle formed by the arc of the chain around a sprocket should be equal to
or greater than 120 degrees.
KB=KG-BG=
7. Using the information from the 6 preceding steps, we can find the chain length (In pitch units)
for these 2 sprockets.
Let L represent the chain length in pitches.
L = 2 [BE + ME + KB] = 2[ ]
From the calculations above we know that:
Line AD = 381 Pitch Units
Line BE = 35.56 Pitch Units
Arc ME = 5.862 Pitch Units
Arc KB = 3.138 Pitch Units
Angle a = 27.24 Degrees

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We can combine all the calculations above into a single more elegant expression of the chain
length (In pitch units) between any 2 sprockets;
[ ( )]
[ ( )]
Solving for L we find
L=67.77
The calculated chain length is 67.77pitch units. Since each pitch unit represents 1 chain link, and
it is not possible to have a fractional link, we must round off the chain length to a whole number.
Remember, it is best practice to use EVEN numbers of chain links. The (final) chain length in
this example becomes 70 chain links.
Note: Do not round down. This causes the chain to be too tight and the added tension can
damage sprockets, shafts and cause premature chain failure.
A length of 80chain links will leave excessive “Play” or slack in the chain drive. This slack will
have to be taken up with a spring-loaded idler sprocket or other chain-tensioning device. The
preferred method for solving this drive design is to recalculate the center to center distance of the
sprocket so that the chain length results in an even and whole number of pitch units. In this case
the desired chain length that will yield a center distance closest to 24for these 2 sprockets would
be 70 pitch units.
Calculating Center Distance from a Known Chain Length
This requires that we rewrite the formula in step 7 in terms of C (The required center distance).
The desired chain length is 70 links or pitch units. This formula can be used to find the center
distance for any given chain length and sprocket set.
C = Center Distance in Pitch Units
L = Chain Length in Links or Pitch Units
N = Number of Teeth of the Large Sprocket
N = Number of Teeth of the Small Sprocket

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( ) ( )
( ) ( )
C=23.81mm
Figure 32 dimension of 06B-1 sprocket
3.11.3 Design of sprocket
The sprocket ratio in this case is given as 2.5:1. The Drive Sprocket must turn 2.5 revolutions
before the Driven Sprocket turns 1.
Ratio=
Used chain no.06B

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For n(driving sprocket=10
Pitch, P=6.35
Width between inner plates, b1=5.72
Roller diameter, d1=7.75
Transverse pitch pt=12.70
pitch circle diameter D =41.10 mm
N (driven sprocket)=10
n (number of drive sprocket)=30
Table 3.Figure 33.dimension of sprocket
Figure 34dimension of 06B sprocket

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3.12.4Shaft calculations
P = 0.25 KW =250 W
K1 = 1.75
N= 100 rpm
Figure 35.dimension of shaft
=
P=0.25
Kw=253W
N=100 rpm
= (60*10^6*0.25*1.75) / (2*π*100)
( )
= 41778.17256 Nmm
= 41.77817256 Nm
Maximum Stress
= ( )
= 0.30* Syt
For Shaft SAE 1030 (Mild steel)
Syt = 296 Mpa
Take F.S = 2

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Mass of Sprocket, W = 2.943 N
Mass of wheel W = 42.183 N
Reactions at Support
Moment at A
RB = 65.62 N
Resultant force in vertical
Shear Force Calculation
Bending moment Calculations
Bending moment at A
Bending moment at X
Bending moment at B

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Bending moment at Y
Bending moment is maximumat point X
Therefore, Resultant Bending moment =
( ) ( )
Selecting Diameter = 20 mm for safe loading and to affix rigidly in pedestal bearing and also for
fixing air valves and rotary coupling on it.
3.12.5 Calculation for air valve sizing
assuming pressure drop and negligible pressure leaks ,industry technical bulletin proposed
equation 1 and 2 depending on pressure drop to determine coefficient of flow (cv),where G is the
specific gravity relative to air at atmospheric condition ,T is the temperature of gas through the
valve in farhanit,p1 and p2 are inlet and outlet pressure psi respectively and p is the pressure
drop through the valve in psi as 27 well. Equation 1 is used if the pressure drop across the valve
is less than half of the inlet pressure and equats- l7ion 7 is used if the pressure drop exceeds half
the inlet pressure in the case where pressure drop exceeds half the inlet pressure, the flow rate is
limited by supper sonic flow and therefore only depends on the inlet pressure.
=
√ ( )
( )
……………..equation 1
=
√ ( )
……………..equation 2
3.12.6 Vibration analysis deflection due to resonance
in performing the vibration analysis one potential failure mode of the rotary joint system that was
identified dealt with excessively largely deflection of the CV joint shaft to which the rotary joint
is attached these large deflection would only occur if the angular velocity of the tire(and hence
CV joint shaft) matched the natural frequency of the rotary joint and shaft system or more
specially if
wtire Where wn is the natural frequency of the rotary joint shaft system and wire is the
angular velocity at which the tire is operating. The condition that leads to large shaft deflections
is known as resonance and if this occurs catastrophic failure due to shear is likely. In order to

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alleviate this problem the natural frequency of the system (also known as the critical speed)
should always be the tire or more specifically
Wcri>wtire
Where wcrit is the critical speed of the rotary joint shaft system and tire represent the some
quantity previously mentioned. This design problem has been modeled based on the following
assumption;
1. The CV joint shaft can be considered as a solid steel cylinder.
2. Only half of the rotary joint (the portion located on the CV joint shaft) rotates the other half
which is attached to the specific at the base of vehicle strut is stationary.
3. The rotating portion of the rotary joint can be modeled as an aluminum rotating dick with the
initial dimension as indicated in the CAD drawing and the mass eccentricity introduced by the
presence of the air tube connection can be considered negligible for this specific problem.
4. The vehicle (and hence tire) speeds cannot exceed 60KMPS,which corresponds TO the worst
case design scenario.
5. The tires can be modeled as p25/65/15 grade as used on the Toyota Camry.
The procedure of this analysis can therefore be summarized as the following;
1. Determine the maximum angular velocity of the tire.
2. Determine the critical speed of the rotary shaft system
3. Compare the critical speed with the maximum angular velocity. if the critical speed r the
maximum angular velocity then the design criterion is satisfied if the critical speed is less
than 28 the maximum angular velocity then the dimension of the rotary joint must be
changed such that the critical speed exceeds the maximum angular velocity.
4. The first item needed to calculate the angular velocity of the tire is the radius of the tire
knowing the grade of the tire for this application the radius can simply be found by
……..equation3
Where w(tire) refers to the width of the tire in inches
D rim refers to the diameter of the rim in inches and
R tire refers to the radius of the tire in inches
Note that the coefficient of the w (tire) is merely the aspect ratio of the height and width of the
tire, which is stated in the tire grade with w(tire)=205mm and d(rim)=15 in C, the radius of the
tire is

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( ( ) ( )
…………………….equaation4
The angular velocity of the tire is then expressed as the following:
…………………………..equation 5
Where is the velocity of the tire in mph,
is the radius of the tire in inches,
is the angular velocity of the tire in rpm,with =37.5mph and =12.75 in the angular
velocity of the tire is
( )( )( )
( )
………………………………..equation 5
In determining the critical speed of the rotary joint shaft system the first step is to determine the
stiffness of the shaft. This quantity can be found by
…………………………………………..EQUATION 6
Where E is the elastic modulus of the shaft in kpsi,
A shaft is the cross section area of the shaft in square inch
L(shaft) is the length of the shaft in inches
K is the stiffness of the shaft I lb/in with E=30000kpsi and L(shaft)=40in, the stiffness of the
shaft is
( ( )( )( ) )
…………………………………..eqution 6
The next phase is to calculate the mass of the rotating portion of the rotary joint according to the
equation.
Where is the density of the disk in ⁄ ,
V(disk) is the initial volume(given in CAD drawing)of the disk in

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g is the gravitational acceleration in ⁄
m is the mass of the disk in ⁄ with =0.098 ⁄ the mass of disk is
( ) ( )
(Note detailed volume calculation omitted due to excessive length)
Finally the critical speed of the rotary joint shaft system can be determined by
√ ……………………..equation 6
Where k and m are the same quantities calculated above and
is the critical speed of the system in rpm with k=7.36*105 ⁄ and m=
0.02 ⁄ ,the critical speed of the system is
√
( )( )
( )( )
=195883.70rpm
Because the critical speed is on the order of 100 times greater than the maximum angular
velocity of the shaft it can be stated that the rotary joint shaft system is more than sufficiently
stable. An optimization on this to reduce the critical speed from an apparent over design situation
is made possible by increasing the overall size of the rotary joint.
3.13APPLICATIONS
1. It can be used in military vehicle.
2. It can be used in emergency vehicle like ambulance, police vehicle and fire vehicle.
3. It can be used in truck and trailers.
4. It can be used in very costly vehicle where maintenance of standard is important.
5. It can be used in sports cars car as there is need of regular checking of air pressure in
tires.

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3.14 Raw material cost:-
We have to search for the suitable available material as per the requirement of designed safe
values. We have searched the material as follows:-
Hence the cost of the raw material is as follows:-
3.14.1 RAW MATERIAL & STANDARD MATERI
Table 2. RAW MATERIAL & STANDARD MATERIAL
SR NO PART NAME MAT COST
1 FRAME MS 3000
2 CHAIN DRIVE 6.25” PITCH S 700
3 SHAFT DIA 20 MM MS 650
4 12 V DC MOTOR MS 1700
5 WHEEL STD 2200
6 BATTERY RU 1500
7 COMPRESSER STD 3000
8 ROTARY VALVE STD 2800
9 PRESSURE GAUGE STD 450
10 PEDESTAL BEARING P204 700
11 NUT BOLT WASHER M 10 MS 120
12 SPROCKET CS 400
13 Solenoid valve CS 150
14 Pressure relif valve CS 206
TOTAL 17576

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3.15 RESULT
Proper tire pressure this always help to improve the tire life attains greater braking
efficiency improved ride quality and cargo safety due to reduction in the vehicle vibration
improve vehicle mobility due to the increase in traction when tire pressure are lowered
.when the required pressure in the tire is reached the buzzer will indicate it to the driver
and the solenoid valve will shut off the air supply to the tire. Thus on implementing the
tire pressure inflation system to the four wheeler vehicle the system will help the driver to
regulate and maintain proper pressure inside the tire. The development of tire pressure
system has proven that user inflate their tire more frequently at home over the weekends
and found to be as an easier application toward sustain correct tire pressure at all time. its
ability to relief excessive air from over inflated tire is also full utilized as hooking up
automatic tire pressure inflation system to the value without any other device are taken as
advantage. The tire pressure inflation system is working with satisfactory condition.

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Chapter four
4 GENERAL CONCLUSIONS AND RECOMMENDATION
4.1CONCLUSION
From the overall internship experience, we can conclude that practical applications are very important and
unforgettable. We develop our knowledge on how theoretical studies are related to practical applications
and we are initiated to perform a better effort for the future.
Regarding this, we can say that we had a successful and interesting time during our internship
experience.
The project carried out by us made an impressing task in the field of automobile field. This
project will reduce the cost involved in the concern. Project has been designed to perform the
entire requirement task at the shortest time available. In this project is used to all the automobile
vehicles. Now the project is designed to the ideal condition vehicles. Then our project developed
to the next level of running condition vehicle. Because of Their vehicles will be a running
condition some times to puncturing the tyre. So the alternative sensors are used to their process.
Then the air will be filled in the tyre pressure per the seconds. They calculate and the air filling
efficiency and to find out the punctured tyres. So easily identified the punctured and to solve the
problems. In this process is an advanced technique of our project.
We can conclude that this system that this system ensure us that each and every tire is properly
inflated to the proper tire pressure throughout the journey and it also improve tire life reduce tire
wear increases fuel efficiency and also increases the overall safety of the vehicle it also monitors
the tire pressure constantly provide us the proper inflation and deflation of the tire and help in
providing a comfortable ride with better mileage.
4.2Recommendation
Based on the experience we have acquired and the time we spend in the internship program we
would like to recommend a few things to University of Gondar
 The University should arrange some practical visit in some courses before or after the
internship program. Because it helps the students to understand what they have
learned in laboratory and lecture classes easily.
 Our university should have a close coordination and inter-company relationship while
weare in the internship program with the hosting companies.
we recommend that, the AWWCE should solve the problems it faced by the following means By
employing a trained mechanics in order to reduce power losses, life transition system,big time losses such
as easily movable use system mechanism.

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 By replacing man power partially by modern system such as simple machine like automatic tire
inflation By fulfilling all spare parts that are necessary for work
 By avoid lack organizational arrangement in the company
4.3Part and assembly drawing

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TIRE
WHEEL
BEARING

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ROTARY JOINT
FILEXBLE HOZE

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FRAME
PRESSURE SENSOR

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SPROCKET OF DERIVEN
CHANE

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DRIVEN SPROCKET

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3D DRAWING

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REFFERANCE
1. WWW.GOOGLE.COM
2. [P.Omprakash, T.Senthil Kumar, “M.A.R.S -Mechanized Air Refilling System”.
3. Case study on AUTOMATIC TYRE INFLATION MANAGEMENT.
4. ALEXANDER VARGHESE, “Influence of Tyre Inflation Pressure on Fuel
Consumption, Vehicle Handling and Ride Quality Modeling and Simulation”.
5. John Woodrooffe, “EFFECTS OF TIRE INFLATION PRESSURE AND CTI ON
ROAD LIFE AND VEHICLE STABILITY”.
6.Inderjeet Singh, Bhupendra Pratap Singh, Hari Shankar Sahu, Raunak Chauhan, Novel
Kumar Sahu. To Study on Implementation of Tyre Inflation System for Automotive
Vehicles. Volume 5 Number 4 2016.
7. Ajas.M.A, Aishwarya.T.G, Adersh Vinayak, Surya Balakrishnan, Janahanlal P.S. Tire
Pressure Monitoring and Air Filling System. International Journal of Reszarch in
Engineering and advanced Technology. Volume 2 Number 2 2014.
8. Hemant Soni, Akash Lahurgade, Sourabh Relkar, Sourabh Badhulkar. Automatic Tire
Inflation System. Golden Research Thoughts Volume 3 Number 10 2014.
9. www.tiresizecalculator.com
10.T Pletts, Literature Review on Central Tyre Inflation System July 2006.

AUTOMATIC TIRE INFLATION SYSTEM DESIGN PROJECT

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