Compressed airengines seminar report
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About This Presentation
Compressed airengines seminar report by saurabh singh
Slide Content
i
COMPRESSED AIR ENGINES
A Seminar Report Submitted In Partial Fulfillment Of
The Requirement For the Degree of
BECHLOR OF TECHNOLOGY
In
Mechanical Engineering
By
SAURABH SINGH
1416440130
Under The Supervision Of
Mr. GAURAV KUMAR UPADHYAY
Assistant Professor
Department Of Mechanical Engineering
PANVEER SINGH INSTITUTE OF TECHNOLOGY,KANPUR
OCTOBER-2016
SESSION 2014-2018
COMPRESSED AIR ENGINES
A Seminar Report Submitted In Partial Fulfillment Of
The Requirement For the Degree of
BECHLOR OF TECHNOLOGY
In
Mechanical Engineering
By
SAURABH SINGH
1416440130
Under The Supervision Of
Mr. GAURAV KUMAR UPADHYAY
Assistant Professor
Department Of Mechanical Engineering
PANVEER SINGH INSTITUTE OF TECHNOLOGY,KANPUR
OCTOBER-2016
SESSION 2014-2018
ii
CERTIFICATE
Certified that Saurabhsingh( Roll Number-1416440130 ) has carried out the seminar work
presented in this seminar entitled “Air Compressed engine” from Pranveer Singh Institute
of Technology, Kanpur, affiliated by A.I.C.T.E and Uttar Pradesh Technical University,
Lucknow under my supervision. The seminar work embodies result of original work, and
studies are carried out by the student himself and the contents of the work do not form the
basis of award of any other degree to the candidate or to anybody else from this or any other
University/Institution.
DR. NITIN SRIVASTAVA Mr. GAURAV KUMAR UPADHYAY
(Head of department) (Assistant Professor)
Department Of Mechanical Engineering Department Of Mechanical Engineering
P.S.I.T KANPUR P.S.I.T KANPUR
DATE-
CERTIFICATE
Certified that Saurabhsingh( Roll Number-1416440130 ) has carried out the seminar work
presented in this seminar entitled “Air Compressed engine” from Pranveer Singh Institute
of Technology, Kanpur, affiliated by A.I.C.T.E and Uttar Pradesh Technical University,
Lucknow under my supervision. The seminar work embodies result of original work, and
studies are carried out by the student himself and the contents of the work do not form the
basis of award of any other degree to the candidate or to anybody else from this or any other
University/Institution.
DR. NITIN SRIVASTAVA Mr. GAURAV KUMAR UPADHYAY
(Head of department) (Assistant Professor)
Department Of Mechanical Engineering Department Of Mechanical Engineering
P.S.I.T KANPUR P.S.I.T KANPUR
DATE-
iii
ABSTRACT
Nowadays, automobiles consume a large number of fossil fuels. However, the consumption
of fossil fuels has brought many serious environmental problems, such as global warming,
ozone layer depletion and fine particulate matter. To avoid such environmental problems,
renewable energy has been applied to automobiles. An air-powered engine of a renewable
energy vehicle is introduced. To lay a foundation for the optimization of compressed air
engine (CAE), a physical model of compressed air engine (CAE) is established with cam
which controls compressed air charge or discharge cylinder. To obtain performance of the
CAE, a prototype CAE system is set up. The output torque, power and efficiency are obtained
through experimental study. The results show that the prototype of CAE has a good economic
performance under low speed and when the supply pressure is 2 MPa, the maximum output
power is 1.92 kW; the maximum output torque is 56.55 N∙m; and the maximum efficiency is
25%. This research can be referred to in the optimization of air-powered engine.
ABSTRACT
Nowadays, automobiles consume a large number of fossil fuels. However, the consumption
of fossil fuels has brought many serious environmental problems, such as global warming,
ozone layer depletion and fine particulate matter. To avoid such environmental problems,
renewable energy has been applied to automobiles. An air-powered engine of a renewable
energy vehicle is introduced. To lay a foundation for the optimization of compressed air
engine (CAE), a physical model of compressed air engine (CAE) is established with cam
which controls compressed air charge or discharge cylinder. To obtain performance of the
CAE, a prototype CAE system is set up. The output torque, power and efficiency are obtained
through experimental study. The results show that the prototype of CAE has a good economic
performance under low speed and when the supply pressure is 2 MPa, the maximum output
power is 1.92 kW; the maximum output torque is 56.55 N∙m; and the maximum efficiency is
25%. This research can be referred to in the optimization of air-powered engine.
iv
ACKNOWLEDGEMENT
I wish to exprssed my sincere gratitude to Mr. Gaurav Upadhyay, Assistant professor,
Depaertment of Mechanical Engineering, Pranveer Singh Institute of Technology, for
providing me kind guidence, contineous encouragement, extend and help support
during my this work.
I would also like to offer thanks to Dr. S.L Shukla Director of Academics, Pranveer
Singh Institute of Technology, Kanpur allowing me to do this work.
I would also like to offer thanks to Dr. Nitin Srivastava Head of Department of
Mechanical Engineering, Pranveer Singh Institute of Technology, Kanpur allowing me
to do this work.
I am also thankful to all the faculty member of Pranveer Singh Institute of Technology,
kanpur for providing me various kind of support or help directly or indirectly, during
my present work.
Saurabh Singh
ACKNOWLEDGEMENT
I wish to exprssed my sincere gratitude to Mr. Gaurav Upadhyay, Assistant professor,
Depaertment of Mechanical Engineering, Pranveer Singh Institute of Technology, for
providing me kind guidence, contineous encouragement, extend and help support
during my this work.
I would also like to offer thanks to Dr. S.L Shukla Director of Academics, Pranveer
Singh Institute of Technology, Kanpur allowing me to do this work.
I would also like to offer thanks to Dr. Nitin Srivastava Head of Department of
Mechanical Engineering, Pranveer Singh Institute of Technology, Kanpur allowing me
to do this work.
I am also thankful to all the faculty member of Pranveer Singh Institute of Technology,
kanpur for providing me various kind of support or help directly or indirectly, during
my present work.
Saurabh Singh
v
1416440130
CONTENTS
CHAPTER-1BRIEF DISCRIPTION
INTRODUCTION ............................................................................................. 1
HISTORY OF COMPRESSED AIR ENGINE .................................................. 1
COMPRESSED AIR ......................................................................................... 3
BEHAVIOR OF COMPRESSE D AIR ................................................................ 3
COMPRESSED AIR ENGINE ........................................................................... 3
CHAPTER-2 WORKING AND PRINCIPLE
THE PRINCIPLE OF COMPRESSED AIR ENGINE ....................................... 5
WORKING OF COMPRESSED AIR ENGINE (CAE) ..................................... 9
COMPRESSED AIR TECHNOLOGY ............................................................ 10
CHAPTER-3 COMPONENTS OF CAE
CONSTRUCTION OF COMPRESSED AIR ENGINE ................................... 12
PNEUMATIC CYLINDER ENGINE .............................................................. 12
PNEUMATIC SOLENOID VALVE AND WORKING .................................. 12
LIGHT CHASER CIRCUIT AND ITS COMPONENT ................................... 12
COMPRESSOR ............................................................................................... 12
TYPES OF COMPRESSOR ............................................................................ 13
CRANK SHAFT .............................................................................................. 17
CHAPTER-4 FUTURE ASPECTS
1416440130
CONTENTS
CHAPTER-1BRIEF DISCRIPTION
INTRODUCTION ............................................................................................. 1
HISTORY OF COMPRESSED AIR ENGINE .................................................. 1
COMPRESSED AIR ......................................................................................... 3
BEHAVIOR OF COMPRESSE D AIR ................................................................ 3
COMPRESSED AIR ENGINE ........................................................................... 3
CHAPTER-2 WORKING AND PRINCIPLE
THE PRINCIPLE OF COMPRESSED AIR ENGINE ....................................... 5
WORKING OF COMPRESSED AIR ENGINE (CAE) ..................................... 9
COMPRESSED AIR TECHNOLOGY ............................................................ 10
CHAPTER-3 COMPONENTS OF CAE
CONSTRUCTION OF COMPRESSED AIR ENGINE ................................... 12
PNEUMATIC CYLINDER ENGINE .............................................................. 12
PNEUMATIC SOLENOID VALVE AND WORKING .................................. 12
LIGHT CHASER CIRCUIT AND ITS COMPONENT ................................... 12
COMPRESSOR ............................................................................................... 12
TYPES OF COMPRESSOR ............................................................................ 13
CRANK SHAFT .............................................................................................. 17
CHAPTER-4 FUTURE ASPECTS
vi
TEST APPARATUS........................................................................................ 18
ADVANTAGES .............................................................................................. 19
DISADVANTAGES ........................................................................................ 20
AIR COMPRESSED ENGINE IN INDIA ...................................................... 20
OTHER DEVELOPMENT IN COMPRESSED AIR TECHNOLOGY ........... 21
CONCLUSION ............................................................................................... 22
REFERENCES ................................................................................................ 23
LIST OF TABLE
Table 1 :The equipment of CAE automobile…………........................................7
TEST APPARATUS........................................................................................ 18
ADVANTAGES .............................................................................................. 19
DISADVANTAGES ........................................................................................ 20
AIR COMPRESSED ENGINE IN INDIA ...................................................... 20
OTHER DEVELOPMENT IN COMPRESSED AIR TECHNOLOGY ........... 21
CONCLUSION ............................................................................................... 22
REFERENCES ................................................................................................ 23
LIST OF TABLE
Table 1 :The equipment of CAE automobile…………........................................7
vii
LIST OF FIGURES
Figure:1 Some early compressed air vehicles…………………………………………………2
Figure 2: Mekarski Compressed Air Tram…………………………………………………… .2
Figure 3: Compressed air engine………………………………………………………………4
Figure 4: The construction of compressed air engine (CAE)………………………………….6
Figure 5 :The ideal schematic diagram of CAE automobile…………………………………..7
Figure 6 :The ideal thermodynamic process of CAE………………………………………….8
Figure 7: Compressed Air Engine with modified tank………………………………………...9
Figure 8:Energy Released As A Function Of Compressed
Pressure At Constant Volume……………………………………………………………….10
Figure 9: 3D-Diagram of an Engine that operated by compressed air……………………….11
Figure 10: Reciprocating Single Acting Compressor………………………………………..13
Figure 11(a): Reciprocating Two-stage, Four Cylinder……………………………………..13
Figure 11(b): Reciprocating Two-stage, Two Cylinder……………………………………..14
Figure 11(c): Reciprocating Single Stage, Oil-less………………………………………….14
Figure 12: Rocking Piston Type……………………………………………………………...15
Figure 13: Diaphragm Type………………………………………………………………….15
Figure 14: Rotary Sliding Vane Type………………………………………………………..16
Figure 15: Rotary Helical Screw Type…………………………………… ………………….17
Figure 16: Rotary Scroll Type………………………………………………………………..17
Figure 17: Experimental setup for characterization of blow gun…………………………….19
Figure 18: Compressed air car for India……………………………………………………...21
Figure 19: PHEV in Republic of Korea……………………………………………………...21
LIST OF FIGURES
Figure:1 Some early compressed air vehicles…………………………………………………2
Figure 2: Mekarski Compressed Air Tram…………………………………………………… .2
Figure 3: Compressed air engine………………………………………………………………4
Figure 4: The construction of compressed air engine (CAE)………………………………….6
Figure 5 :The ideal schematic diagram of CAE automobile…………………………………..7
Figure 6 :The ideal thermodynamic process of CAE………………………………………….8
Figure 7: Compressed Air Engine with modified tank………………………………………...9
Figure 8:Energy Released As A Function Of Compressed
Pressure At Constant Volume……………………………………………………………….10
Figure 9: 3D-Diagram of an Engine that operated by compressed air……………………….11
Figure 10: Reciprocating Single Acting Compressor………………………………………..13
Figure 11(a): Reciprocating Two-stage, Four Cylinder……………………………………..13
Figure 11(b): Reciprocating Two-stage, Two Cylinder……………………………………..14
Figure 11(c): Reciprocating Single Stage, Oil-less………………………………………….14
Figure 12: Rocking Piston Type……………………………………………………………...15
Figure 13: Diaphragm Type………………………………………………………………….15
Figure 14: Rotary Sliding Vane Type………………………………………………………..16
Figure 15: Rotary Helical Screw Type…………………………………… ………………….17
Figure 16: Rotary Scroll Type………………………………………………………………..17
Figure 17: Experimental setup for characterization of blow gun…………………………….19
Figure 18: Compressed air car for India……………………………………………………...21
Figure 19: PHEV in Republic of Korea……………………………………………………...21
viii
1
CHAPTER-1 BRIEF DISCRIPTION
INTRODUCTION
FOSSIL fuels (i.e., petroleum, diesel, natural gas and coal) which meet most of the world's
energy demand today are being depleted rapidly. Also, theircombustion products are causing
global problems,such as the green house effect, ozone layer depletionacid rains and pollution
which are posing great danger for environment and eventually for the total life onplanet.
These factors are leading automobile manufactures to develop cars fueled by alternatives
energies. Hybrid cars, Fuel cell powered cars, Hydrogen fueled cars will be soon in the
market as a result of it. One possible alternative is the air powered car. Air, which is
abundantly available and is free from pollution, can be compressed to higher pressure at a
very low cost, is one of the prime option since atmospheric pollution can be permanently
eradicated. Whereas so far all the attempts made to eliminate the pollution has however to
reduce it, but complete eradication is still rigorously pursued. Compressed air utilization in
the pneumatic application has been long proven. Air motors, pneumatic actuators and
others various such pneumatic equipments are in use. Compressed air was also used in some
of vehicle for boosting the initial torque. Turbo charging has become one of the popular
techniques to enhance power and improve the efficiencies of the automotive engine that
completely runs on compressed air. There are at two ongoing projects (in France, by MDI
and in S. Korea) that are developing a new type of car that will run only on compressed air.
Similar attempt has been made but to modify the existing engine and to test on compressed
air
[1]
.
HISTORY OF COMPRESSED AIR ENGINE
One cannot accurately claim that compressed air as an energy and locomotion vector is recent
technology. At the end of the 19th century, the first approximations to what could one day
become a compressed air driven vehicle already existed, with the arrival of the first
pneumatic locomotives. In fact, two centuries beforethat Dennis Papin apparently came up
with the idea of using compressed air (Royal Society London, 1687). In 1872 the Mekarski
air engine was used for street transit, consisting of a singlestage engine. It represented an
extremely important advance in terms of pneumatic engines, due to its forward thinking use
of thermodynamics, which ensured that the air was heated, by passing it through tanks of
boiling water, which also increased its range between fill-ups. Numerous locomotives
were manufactured and a number of regular lines were opened up (the first in Nantes in
1879). In 1892, Robert Hardie introduced a new method of heating that at the same time
served to increase the range of the engine.
However, the first urban transport locomotive was not introduced until 1898, by Hoadley and
Knight, and was based on the principle that the longer
the air is kept in the engine the more heat it absorbs and the greater its range. As a result they
introduced a two-stage engine.
Charles B. Hodges will always be remembered as the true father of thecompressed air
concept applied to cars, being the first person, not only to invent a car driven by a
compressed air engine but also to have considerable commercial success with it. The H.K.
Porter Company of Pittsburgh sold hundreds of these vehicles to the mining industry in the
eastern United States, due to the safety that this method of propulsion represented for the
CHAPTER-1 BRIEF DISCRIPTION
INTRODUCTION
FOSSIL fuels (i.e., petroleum, diesel, natural gas and coal) which meet most of the world's
energy demand today are being depleted rapidly. Also, theircombustion products are causing
global problems,such as the green house effect, ozone layer depletionacid rains and pollution
which are posing great danger for environment and eventually for the total life onplanet.
These factors are leading automobile manufactures to develop cars fueled by alternatives
energies. Hybrid cars, Fuel cell powered cars, Hydrogen fueled cars will be soon in the
market as a result of it. One possible alternative is the air powered car. Air, which is
abundantly available and is free from pollution, can be compressed to higher pressure at a
very low cost, is one of the prime option since atmospheric pollution can be permanently
eradicated. Whereas so far all the attempts made to eliminate the pollution has however to
reduce it, but complete eradication is still rigorously pursued. Compressed air utilization in
the pneumatic application has been long proven. Air motors, pneumatic actuators and
others various such pneumatic equipments are in use. Compressed air was also used in some
of vehicle for boosting the initial torque. Turbo charging has become one of the popular
techniques to enhance power and improve the efficiencies of the automotive engine that
completely runs on compressed air. There are at two ongoing projects (in France, by MDI
and in S. Korea) that are developing a new type of car that will run only on compressed air.
Similar attempt has been made but to modify the existing engine and to test on compressed
air
[1]
.
HISTORY OF COMPRESSED AIR ENGINE
One cannot accurately claim that compressed air as an energy and locomotion vector is recent
technology. At the end of the 19th century, the first approximations to what could one day
become a compressed air driven vehicle already existed, with the arrival of the first
pneumatic locomotives. In fact, two centuries beforethat Dennis Papin apparently came up
with the idea of using compressed air (Royal Society London, 1687). In 1872 the Mekarski
air engine was used for street transit, consisting of a singlestage engine. It represented an
extremely important advance in terms of pneumatic engines, due to its forward thinking use
of thermodynamics, which ensured that the air was heated, by passing it through tanks of
boiling water, which also increased its range between fill-ups. Numerous locomotives
were manufactured and a number of regular lines were opened up (the first in Nantes in
1879). In 1892, Robert Hardie introduced a new method of heating that at the same time
served to increase the range of the engine.
However, the first urban transport locomotive was not introduced until 1898, by Hoadley and
Knight, and was based on the principle that the longer
the air is kept in the engine the more heat it absorbs and the greater its range. As a result they
introduced a two-stage engine.
Charles B. Hodges will always be remembered as the true father of thecompressed air
concept applied to cars, being the first person, not only to invent a car driven by a
compressed air engine but also to have considerable commercial success with it. The H.K.
Porter Company of Pittsburgh sold hundreds of these vehicles to the mining industry in the
eastern United States, due to the safety that this method of propulsion represented for the
2
mining sector. Later on, in 1912, the American’s method was improved by Europeans, adding
a further expansion stage to the engine - 3 stages
[2]
.
Figure 1: Some early compressed air vehicles
Figure 2: Mekarski Compressed Air Tram
mining sector. Later on, in 1912, the American’s method was improved by Europeans, adding
a further expansion stage to the engine - 3 stages
[2]
.
Figure 1: Some early compressed air vehicles
Figure 2: Mekarski Compressed Air Tram
3
COMPRESSED AIR
Compressed air is a gas, or a combination of gases, that has been put under greater pressure
than the air in the general environment. Numerous and diverse, including jack hammers, tire
pumps, air rifles, and aerosol cheese are some of the current applications using compressed
air. In this case Compressed air can also be defined as the fuel having the potential as a clean,
inexpensive, and infinitely renewable energy source. Its use is currently being explored and
can be an alternative to fossil fuels.
BEHAVIOR OF COMPRESSED AIR
Compressed air is clean, safe, simple and efficient. There are no dangerous exhaust fumes of
or other harmful by products when compressed air is used as a utility. It is a non-combustible,
non-polluting utility. When air at atmospheric pressure is mechanically compressed by a
compressor, the transformation of air at 1 bar (atmospheric pressure) into air at higher
pressure (up to 414 bar) is determined by the laws of thermodynamics. They state that an
increase in pressure equals a rise in heat and compressing air creates a proportional increase
in heat. Boyle's law explains that if a volume of a gas (air) halves during compression, then
the pressure is doubled. Charles' law states that the volume of a gas changes in direct
proportion to the temperature. These laws explain that pressure, volume and temperature are
proportional; change one variable and one or two of the others will also change, according to
this equation:
(P1 V1) / T1 = (P2 V2)/T2
Compressed air is normally used in pressure ranges from 1 bar to 414 bar (14 to 6004 PSI) at
various flow rates from as little as 0.1 m (3.5 CFM -cubic feet per minute) and up
[3]
.
COMPRESSED AIR ENGINE
This engine was developed between the end of 2001 and the beginning of 2002. It uses an
innovative system to control the movement of the 2nd generation pistons and one single
crankshaft. The pistons work in two stages-one motor stage and one intermediate stage of
compression/expansion. The engine has 4 two-stage pistons, i.e. 8 compression and/or
expansion chambers. They have two functions: to compress ambient air and refill the storage
tanks; and to make successive expansions (reheating air with ambient thermal energy)
thereby approaching isothermal expansion. Figure 3 shows the compressed air engine.
Two technologies have been developed to meet different needs:
Single energy compressed air engines; and
Dual energy compressed air plus fuel engines.
The single energy engines will be available in both Minicats and Citycats. These engines
have been conceived for city use, where the maximum speed is 50 km/h and where MDI
believes polluting will soon be prohibited. The dual energy engine, on the other hand,
has been conceived as much for the city as the open road and will be available in all MDI
vehicles. The engines will work exclusively with compressed air while it is running under 50
km/h in urban areas. But when the car is used outside urban areas at speeds over 50 km/h, the
engines will switch to fuel mode. The engine will be able to use gasoline, gas oil, bio-diesel,
gas, liquidized gas, ecological fuel, alcohol, etc. Both engines will be available with
COMPRESSED AIR
Compressed air is a gas, or a combination of gases, that has been put under greater pressure
than the air in the general environment. Numerous and diverse, including jack hammers, tire
pumps, air rifles, and aerosol cheese are some of the current applications using compressed
air. In this case Compressed air can also be defined as the fuel having the potential as a clean,
inexpensive, and infinitely renewable energy source. Its use is currently being explored and
can be an alternative to fossil fuels.
BEHAVIOR OF COMPRESSED AIR
Compressed air is clean, safe, simple and efficient. There are no dangerous exhaust fumes of
or other harmful by products when compressed air is used as a utility. It is a non-combustible,
non-polluting utility. When air at atmospheric pressure is mechanically compressed by a
compressor, the transformation of air at 1 bar (atmospheric pressure) into air at higher
pressure (up to 414 bar) is determined by the laws of thermodynamics. They state that an
increase in pressure equals a rise in heat and compressing air creates a proportional increase
in heat. Boyle's law explains that if a volume of a gas (air) halves during compression, then
the pressure is doubled. Charles' law states that the volume of a gas changes in direct
proportion to the temperature. These laws explain that pressure, volume and temperature are
proportional; change one variable and one or two of the others will also change, according to
this equation:
(P1 V1) / T1 = (P2 V2)/T2
Compressed air is normally used in pressure ranges from 1 bar to 414 bar (14 to 6004 PSI) at
various flow rates from as little as 0.1 m (3.5 CFM -cubic feet per minute) and up
[3]
.
COMPRESSED AIR ENGINE
This engine was developed between the end of 2001 and the beginning of 2002. It uses an
innovative system to control the movement of the 2nd generation pistons and one single
crankshaft. The pistons work in two stages-one motor stage and one intermediate stage of
compression/expansion. The engine has 4 two-stage pistons, i.e. 8 compression and/or
expansion chambers. They have two functions: to compress ambient air and refill the storage
tanks; and to make successive expansions (reheating air with ambient thermal energy)
thereby approaching isothermal expansion. Figure 3 shows the compressed air engine.
Two technologies have been developed to meet different needs:
Single energy compressed air engines; and
Dual energy compressed air plus fuel engines.
The single energy engines will be available in both Minicats and Citycats. These engines
have been conceived for city use, where the maximum speed is 50 km/h and where MDI
believes polluting will soon be prohibited. The dual energy engine, on the other hand,
has been conceived as much for the city as the open road and will be available in all MDI
vehicles. The engines will work exclusively with compressed air while it is running under 50
km/h in urban areas. But when the car is used outside urban areas at speeds over 50 km/h, the
engines will switch to fuel mode. The engine will be able to use gasoline, gas oil, bio-diesel,
gas, liquidized gas, ecological fuel, alcohol, etc. Both engines will be available with
4
2, 4 and 6 cylinders, When the air tanks are empty the driver will be able to switch to fuel
mode, thanks to the car’s on board computer
[4]
.
Figure 3: Compressed air engine
2, 4 and 6 cylinders, When the air tanks are empty the driver will be able to switch to fuel
mode, thanks to the car’s on board computer
[4]
.
Figure 3: Compressed air engine
5
CHAPTER-2 WORKING AND PRINCIPLE
THE PRINCIPLE OF COMPRESSED AIR ENGINE
A typical single-cylinder CAE, as shown in Figure 4, is composed of an intake valve (shown
by number 1), anexhaust valve (indicated by number 2), a cylinder (indicated by number 3), a
piston (shown by number 4), aconnecting rod (shown by number 5) and a crankshaft (shown
by number 6). In the suction power stroke, compressedair enters the cylinder via the intake
valve because of the pressure difference, drives the piston downward.Then the intake valve
closes when the crank reaches a certain angle. While the compressed air continuesto push the
piston down and output mechanical work. When the movement of piston is close to the
bottom deadcenter (BDC) the exhaust valve opens, so that the compressed air with residual
pressure is expelled by the impetusof the piston. After the piston moves back to the top center
(TDC), the CAE completes a work cycle. The schematic diagram of a CAE automobile
system, as demonstrated in Figure 5, is mainly consist of a CAE, an high pressure air tank,
an buffer tank, two pressure sensors, two regulators, an air operated pressure reliefvalve
(TESCOM), an electronic proportional directional control valve (FAIRCHILD), a silencer, a
signalprocessor. The airflow path starts from the high pressure air tank then through buffer
tank, control valve andeventually accesses the CAE. The airflow mass, entries into the CAE,
is controlled by the valve position. And the valve is managed by externally applied electric
current, denoted by i, when iequals to 4 mA, the valve will be fully closed, and fully open
when iis equal to 20 mA. The major parts of air dynamic system and their functionsare
revealed in Table 1.
CHAPTER-2 WORKING AND PRINCIPLE
THE PRINCIPLE OF COMPRESSED AIR ENGINE
A typical single-cylinder CAE, as shown in Figure 4, is composed of an intake valve (shown
by number 1), anexhaust valve (indicated by number 2), a cylinder (indicated by number 3), a
piston (shown by number 4), aconnecting rod (shown by number 5) and a crankshaft (shown
by number 6). In the suction power stroke, compressedair enters the cylinder via the intake
valve because of the pressure difference, drives the piston downward.Then the intake valve
closes when the crank reaches a certain angle. While the compressed air continuesto push the
piston down and output mechanical work. When the movement of piston is close to the
bottom deadcenter (BDC) the exhaust valve opens, so that the compressed air with residual
pressure is expelled by the impetusof the piston. After the piston moves back to the top center
(TDC), the CAE completes a work cycle. The schematic diagram of a CAE automobile
system, as demonstrated in Figure 5, is mainly consist of a CAE, an high pressure air tank,
an buffer tank, two pressure sensors, two regulators, an air operated pressure reliefvalve
(TESCOM), an electronic proportional directional control valve (FAIRCHILD), a silencer, a
signalprocessor. The airflow path starts from the high pressure air tank then through buffer
tank, control valve andeventually accesses the CAE. The airflow mass, entries into the CAE,
is controlled by the valve position. And the valve is managed by externally applied electric
current, denoted by i, when iequals to 4 mA, the valve will be fully closed, and fully open
when iis equal to 20 mA. The major parts of air dynamic system and their functionsare
revealed in Table 1.
6
Figure 4: The construction of compressed air engine(CAE)
1. Intake valve
2. Exhaust valve
3. Cylinder
4. Piston
5. Connecting rod
6. Crankshaft.
Figure 4: The construction of compressed air engine(CAE)
1. Intake valve
2. Exhaust valve
3. Cylinder
4. Piston
5. Connecting rod
6. Crankshaft.
7
THERMODYNAMIC PROCESS ANALYSIS
Figure 5 :The ideal schematic diagram of CAE automobile
ELEMENTS FUNCTIONS
1 Pressure sensor Calculate the pressure of storage tank
2 High pressure air tank Store up and provide high pressure air
3 Regulator Regulate gas pressure
4 Buffer tank Provide appropriate pressure air to CAE
5 Regulator Regulate gas pressure to meet electronic
proportional
directional control valve pressure
6 Electronic proportional directional control
valve
Modulate the amount of entering air which
controls the elements 7
7 Air operated regulator Modulate the pressure of entering air and
control of CAE
8 Pressure sensor Calculate the pressure of airflow
9 CAE Provide the power
10 Silencer Reduce the noise
11 Controller Measure pressure and output the analog
signal to the electronic control valve
Table 1 :The equipment of CAE automobile
For the CAE, the high pressure air at normal temperature could supply the driving force. The
reason of the shaftwork is the impulse action and the dynamic action of the high compressed
air. Thermodynamically, the processis considered reverse to the course of the piston-type air
compressor. The ideal thermodynamic process can beshown as Figure 6, intake process and
exhaust process are considered constant pressure process, and expansionprocess is considered
adiabatic process. The theoretical work is given as follows.
THERMODYNAMIC PROCESS ANALYSIS
Figure 5 :The ideal schematic diagram of CAE automobile
ELEMENTS FUNCTIONS
1 Pressure sensor Calculate the pressure of storage tank
2 High pressure air tank Store up and provide high pressure air
3 Regulator Regulate gas pressure
4 Buffer tank Provide appropriate pressure air to CAE
5 Regulator Regulate gas pressure to meet electronic
proportional
directional control valve pressure
6 Electronic proportional directional control
valve
Modulate the amount of entering air which
controls the elements 7
7 Air operated regulator Modulate the pressure of entering air and
control of CAE
8 Pressure sensor Calculate the pressure of airflow
9 CAE Provide the power
10 Silencer Reduce the noise
11 Controller Measure pressure and output the analog
signal to the electronic control valve
Table 1 :The equipment of CAE automobile
For the CAE, the high pressure air at normal temperature could supply the driving force. The
reason of the shaftwork is the impulse action and the dynamic action of the high compressed
air. Thermodynamically, the processis considered reverse to the course of the piston-type air
compressor. The ideal thermodynamic process can beshown as Figure 6, intake process and
exhaust process are considered constant pressure process, and expansionprocess is considered
adiabatic process. The theoretical work is given as follows.
8
W5-2 =P1(V1-V2) (1)
W2-3=P1V1/(1-k)[(V3-V2)^(1-k)-1] (2)
W3-5=P4(V1-V3) (3)
Woutput=W5-2+W2-3+W3-5 (4)
where, Wouputtis the theoretical work done, P1 and V2 represent the supply pressure and
volume, respectively, atwhich the air push down the piston downward movement, V1 is the
clearance of cylinder, P3and V3 are the pressureand volume, respectively, up to which the
maximum expansion of air takes place, and P4 is the pressure atwhich the piston discharges
the air to the environment
[5]
.
Figure 6 :The ideal thermodynamic process of CAE
W5-2 =P1(V1-V2) (1)
W2-3=P1V1/(1-k)[(V3-V2)^(1-k)-1] (2)
W3-5=P4(V1-V3) (3)
Woutput=W5-2+W2-3+W3-5 (4)
where, Wouputtis the theoretical work done, P1 and V2 represent the supply pressure and
volume, respectively, atwhich the air push down the piston downward movement, V1 is the
clearance of cylinder, P3and V3 are the pressureand volume, respectively, up to which the
maximum expansion of air takes place, and P4 is the pressure atwhich the piston discharges
the air to the environment
[5]
.
Figure 6 :The ideal thermodynamic process of CAE
9
WORKING OF COMPRESSED AIR ENGINE (CAE)
A compressed air engine is a type of engine which does mechanical work by expanding
compressed air. Pneumatic engine generally convert compressed air energy to mechanical
work either into linear motion or rotatory motion. Where linear motion is come from
diaphragm and rotary motion is come from either a vane type air motor or piston air
motor.Pneumatic motors which are existed in many forms from the past two centuries,
Manycompressed air engines improve their performance by modifying their compressed air
tank and heating the incoming air or the engine itself. The given Figure 7: show a newly
design engine that operated by compressed air, here modification is done with tank where
compressed air is stored.
Approximately 90m
3
of compressed air is stored in fiber tanks in the vehicle. The engine is
powered by compressed air, stored in a carbon-fiber tank at 30 MPa (4500 psi). The tank is
made of carbon fiber in order to reduce its weight. The engine has injection similar to normal
engines, but uses special crankshafts and pistons, which remain at top dead centre for about
70 degrees of the crankshaft’s cycle; this allows more power to be developed in the engine.
The expansion of this air pushes the pistons and creates movement. The atmospheric
temperature is used to re-heat the engine and increase the road coverage. The air conditioning
system makes use of the expelled cold air. Due to the absence of combustion and the fact
there is no pollution, the oil change is only necessary every 50,000 km.
Figure 7: Compressed Air Engine with modified tank
WORKING OF COMPRESSED AIR ENGINE (CAE)
A compressed air engine is a type of engine which does mechanical work by expanding
compressed air. Pneumatic engine generally convert compressed air energy to mechanical
work either into linear motion or rotatory motion. Where linear motion is come from
diaphragm and rotary motion is come from either a vane type air motor or piston air
motor.Pneumatic motors which are existed in many forms from the past two centuries,
Manycompressed air engines improve their performance by modifying their compressed air
tank and heating the incoming air or the engine itself. The given Figure 7: show a newly
design engine that operated by compressed air, here modification is done with tank where
compressed air is stored.
Approximately 90m
3
of compressed air is stored in fiber tanks in the vehicle. The engine is
powered by compressed air, stored in a carbon-fiber tank at 30 MPa (4500 psi). The tank is
made of carbon fiber in order to reduce its weight. The engine has injection similar to normal
engines, but uses special crankshafts and pistons, which remain at top dead centre for about
70 degrees of the crankshaft’s cycle; this allows more power to be developed in the engine.
The expansion of this air pushes the pistons and creates movement. The atmospheric
temperature is used to re-heat the engine and increase the road coverage. The air conditioning
system makes use of the expelled cold air. Due to the absence of combustion and the fact
there is no pollution, the oil change is only necessary every 50,000 km.
Figure 7: Compressed Air Engine with modified tank
10
COMPRESSED AIR TECHNOLOGY
The basic object with Compressed air Technology is to implement in vehicle for consumption
of minimum amount of energy and remain the output work same. In today’s world, everyone
wants to afford a vehicle and it’s energy to power it. Engine air technology makes it happen
from many aspects. It is very less in term of mass as compared with other sources of energy
for transportation of man or material. It also improve urban life style through sustainability
&Non-polluting vehicle. It’s impact on the environment is also considerly low. It remains
with intelligency, lighter, style and comfort. Most of the work done by an air compressor is
during compression stroke. Which will addenergyto the air by increasing its pressure.
Compression also produce heat, however, and the amount of work required to compress a
quantity of air to a given pressure depends on how fast this heat is removed. The compressed
work done will lie between the theoretical work requirements of two processes and they are :-
ADIABATIC
A process which have no cooling and the heat does remains in the air which causing pressure
rise that increases compression work requirements for the maximum value.
ISOTHERMAL
A process that provides perfect cooling, in which no changing in temperature of air and the
work required for compression is tends to the minimum.” But the given fig: indicates that
isothermal expansion is higher than adiabatic expansion, the volume of the compressed air
and flow rate are controlled at a particular compressed pressure
[6]
.
Figure 8:Energy Released As A Function Of Compressed Pressure At
Constant Volume
COMPRESSED AIR TECHNOLOGY
The basic object with Compressed air Technology is to implement in vehicle for consumption
of minimum amount of energy and remain the output work same. In today’s world, everyone
wants to afford a vehicle and it’s energy to power it. Engine air technology makes it happen
from many aspects. It is very less in term of mass as compared with other sources of energy
for transportation of man or material. It also improve urban life style through sustainability
&Non-polluting vehicle. It’s impact on the environment is also considerly low. It remains
with intelligency, lighter, style and comfort. Most of the work done by an air compressor is
during compression stroke. Which will addenergyto the air by increasing its pressure.
Compression also produce heat, however, and the amount of work required to compress a
quantity of air to a given pressure depends on how fast this heat is removed. The compressed
work done will lie between the theoretical work requirements of two processes and they are :-
ADIABATIC
A process which have no cooling and the heat does remains in the air which causing pressure
rise that increases compression work requirements for the maximum value.
ISOTHERMAL
A process that provides perfect cooling, in which no changing in temperature of air and the
work required for compression is tends to the minimum.” But the given fig: indicates that
isothermal expansion is higher than adiabatic expansion, the volume of the compressed air
and flow rate are controlled at a particular compressed pressure
[6]
.
Figure 8:Energy Released As A Function Of Compressed Pressure At
Constant Volume
11
Figure 9: 3D-Diagram of an Engine that operated by compressed air
Figure 9: 3D-Diagram of an Engine that operated by compressed air
12
CHAPTER-3 COMPONENTS OF CAE
CONSTRUCTION OF COMPRESSED AIR ENGINE
The construction of compressed air engine is very easy and simple and can be constructed at
low cost as it mainly consist of pneumatic cylinder, pneumatic solenoid valve and working,
light chaser circuit, compressor, bearing & it’s working, and crank shaft.
PNEUMATIC CYLINDERENGINE
The mechanical devices such as Pneumatic cylinders (sometimes known as air cylinders)
uses the power of compressed gas to produce a force in a reciprocating linear motion. Like
hydraulic cylinders, something forces a piston to move in the desired direction. The piston is
a disc or cylinder, and the piston rod transfers the force it develops to the object to be moved.
Engineers sometimes prefer to use pneumatics because they are quieter, cleaner, and do not
require large amounts of space for fluid storage. Because the operating fluid is a gas, leakage
from a pneumatic cylinder will not drip out and contaminate the surroundings, making
pneumatics more desirable where cleanliness is a requirement.
PNEUMATIC SOLENOID VALVE AND WORKING
A valve which is electromechanically operated is known as solenoid valve. The valve is
controlled by an electric current through a solenoid: in the case of a two-port valve the flow is
switched on or off; in the case of a three-port valve, the outflow is switched between the two
outlet ports. Multiple solenoid valves can be placed together on a manifold. Solenoid valves
are the most frequently used control elements in fluidics. Their tasks are to shut off, release,
dose, distribute or mix fluids. They are found in many application areas. Solenoids offer fast
and safe switching, high reliability, long service life, good medium compatibility of the
materials used, low control power and compact design.
LIGHT CHASER CIRCUIT AND ITS COMPONENT
This light chaser circuit (music-operated lighting effect generator) comprises five sets of
60W bulbs that are arranged in zigzag fashion. The bulb sets glow one after another
depending on the intensity of the audio signal. No electrical connection is to be made
between the music system and the lighting effect generator circuit. You just need to place the
gadget near the speakers of the music system.
COMPRESSOR
A Gas Compressor is a mechanical device whose work is to increase the pressure of a gas
by reducing its volume. An air compressor is specific type of gas compressor. Compressors
are similar to pumps: both the compressor and pump increase the pressure on a fluid and both
can transport the fluid through a pipe. As gases are compressible, the compressor also
reduces the volume of a gas. Liquids are relatively incompressible; while some can be
compressed, to pressurize and transport liquids is the main action of a pump. Compressed air
Piston range operates between 0.75 kW to 420 kW or in horse power is 1hp to 563hp
producing working pressure at 1.5 bar to 414 bar or in PSI is 21 to 6004PSI. Compressed air
CHAPTER-3 COMPONENTS OF CAE
CONSTRUCTION OF COMPRESSED AIR ENGINE
The construction of compressed air engine is very easy and simple and can be constructed at
low cost as it mainly consist of pneumatic cylinder, pneumatic solenoid valve and working,
light chaser circuit, compressor, bearing & it’s working, and crank shaft.
PNEUMATIC CYLINDERENGINE
The mechanical devices such as Pneumatic cylinders (sometimes known as air cylinders)
uses the power of compressed gas to produce a force in a reciprocating linear motion. Like
hydraulic cylinders, something forces a piston to move in the desired direction. The piston is
a disc or cylinder, and the piston rod transfers the force it develops to the object to be moved.
Engineers sometimes prefer to use pneumatics because they are quieter, cleaner, and do not
require large amounts of space for fluid storage. Because the operating fluid is a gas, leakage
from a pneumatic cylinder will not drip out and contaminate the surroundings, making
pneumatics more desirable where cleanliness is a requirement.
PNEUMATIC SOLENOID VALVE AND WORKING
A valve which is electromechanically operated is known as solenoid valve. The valve is
controlled by an electric current through a solenoid: in the case of a two-port valve the flow is
switched on or off; in the case of a three-port valve, the outflow is switched between the two
outlet ports. Multiple solenoid valves can be placed together on a manifold. Solenoid valves
are the most frequently used control elements in fluidics. Their tasks are to shut off, release,
dose, distribute or mix fluids. They are found in many application areas. Solenoids offer fast
and safe switching, high reliability, long service life, good medium compatibility of the
materials used, low control power and compact design.
LIGHT CHASER CIRCUIT AND ITS COMPONENT
This light chaser circuit (music-operated lighting effect generator) comprises five sets of
60W bulbs that are arranged in zigzag fashion. The bulb sets glow one after another
depending on the intensity of the audio signal. No electrical connection is to be made
between the music system and the lighting effect generator circuit. You just need to place the
gadget near the speakers of the music system.
COMPRESSOR
A Gas Compressor is a mechanical device whose work is to increase the pressure of a gas
by reducing its volume. An air compressor is specific type of gas compressor. Compressors
are similar to pumps: both the compressor and pump increase the pressure on a fluid and both
can transport the fluid through a pipe. As gases are compressible, the compressor also
reduces the volume of a gas. Liquids are relatively incompressible; while some can be
compressed, to pressurize and transport liquids is the main action of a pump. Compressed air
Piston range operates between 0.75 kW to 420 kW or in horse power is 1hp to 563hp
producing working pressure at 1.5 bar to 414 bar or in PSI is 21 to 6004PSI. Compressed air
13
Vane compressors operate between 1.1 kW to 75 kW or in horse power 1.5 to 100hp
,producing working pressures of 7 to 8 and 10 bar or in PSI is 101 to145 PSI.
TYPES OF COMPRESSOR
1- Reciprocating Single Acting Compressor
Reciprocating single acting compressors are generally of one-stage or two-stage design.
Compressors can be of a lubricated, non-lubricated or oil-less design. In the single-stage
compressor, air is drawn in from the atmosphere and compressed to final pressure in single
stroke. The single-stage reciprocating compressor is illustrated in(Figure 10). Single-stage
compressors are generally used for pressures of 70 psi (pounds per square inch) to 135 psi.
Figure 10: Reciprocating Single Acting Compressor
2- Reciprocating Single Stage
In the two-stage compressor, air is drawn in from the atmosphere and compressed to an
intermediate pressure in the first stage. Most of the heat of compression is removed as the
compressed air then passes through the intercooler to the second stage, where it is
compressed to final pressure. Two-stage compressors can include two cylinder designs. The
two-stage reciprocating compressor is illustrated in (Figures 11(a) and 11(b)).
Figure 11(a): Reciprocating Two-stage, Four Cylinder
Vane compressors operate between 1.1 kW to 75 kW or in horse power 1.5 to 100hp
,producing working pressures of 7 to 8 and 10 bar or in PSI is 101 to145 PSI.
TYPES OF COMPRESSOR
1- Reciprocating Single Acting Compressor
Reciprocating single acting compressors are generally of one-stage or two-stage design.
Compressors can be of a lubricated, non-lubricated or oil-less design. In the single-stage
compressor, air is drawn in from the atmosphere and compressed to final pressure in single
stroke. The single-stage reciprocating compressor is illustrated in(Figure 10). Single-stage
compressors are generally used for pressures of 70 psi (pounds per square inch) to 135 psi.
Figure 10: Reciprocating Single Acting Compressor
2- Reciprocating Single Stage
In the two-stage compressor, air is drawn in from the atmosphere and compressed to an
intermediate pressure in the first stage. Most of the heat of compression is removed as the
compressed air then passes through the intercooler to the second stage, where it is
compressed to final pressure. Two-stage compressors can include two cylinder designs. The
two-stage reciprocating compressor is illustrated in (Figures 11(a) and 11(b)).
Figure 11(a): Reciprocating Two-stage, Four Cylinder
14
Figure 11(b): Reciprocating Two-stage, Two Cylinder
Single and two-stage reciprocating compressors are frequently used in auto and truck repair
shops, body shops, service businesses and industrial plants. Although this type of compressor
is usually oil lubricated, hospitals and laboratories can purchase oil-less versions of the
compressors as illustrated in Figure 11(c).
Figure 11(c): Reciprocating Single Stage, Oil-less
Figure 11(b): Reciprocating Two-stage, Two Cylinder
Single and two-stage reciprocating compressors are frequently used in auto and truck repair
shops, body shops, service businesses and industrial plants. Although this type of compressor
is usually oil lubricated, hospitals and laboratories can purchase oil-less versions of the
compressors as illustrated in Figure 11(c).
Figure 11(c): Reciprocating Single Stage, Oil-less
15
3- Rocking Piston Type
Rocking piston compressors are variations of reciprocating piston type compressors (Figure
12). This type of compressor develops pressure through a reciprocating action of a one-piece
connecting rod and piston. The piston head rocks as it reciprocates. These compressors utilize
non-metallic, low friction rings and do not require lubrication. The rocking piston type
compressors are generally of a smaller size and lower pressure capability.
Figure 12: Rocking Piston Type
4- Diaphragm Type
Diaphragm compressors (Figure 13) are a variation of reciprocating compressors. The
diaphragm compressor develops pressure through a reciprocating or oscillating action of a
flexible disc actuated by an eccentric. Since a sliding seal is not required between moving
parts, this design is not lubricated. Diaphragm compressors are often selected when no
contamination is allowed in the output air or atmosphere, such as hospital and laboratory
applications. Diaphragm compressors are limited in output and pressure and they are used
most often for light-duty applications.
Figure 13: Diaphragm Type
5- Rotary Sliding Vane Type
The rotary vane compressor consists of a rotor mounted eccentrically in a housing (Figure 14
). As the rotor turns, the vanes slide out by centrifugal force until they seal against a thin film
3- Rocking Piston Type
Rocking piston compressors are variations of reciprocating piston type compressors (Figure
12). This type of compressor develops pressure through a reciprocating action of a one-piece
connecting rod and piston. The piston head rocks as it reciprocates. These compressors utilize
non-metallic, low friction rings and do not require lubrication. The rocking piston type
compressors are generally of a smaller size and lower pressure capability.
Figure 12: Rocking Piston Type
4- Diaphragm Type
Diaphragm compressors (Figure 13) are a variation of reciprocating compressors. The
diaphragm compressor develops pressure through a reciprocating or oscillating action of a
flexible disc actuated by an eccentric. Since a sliding seal is not required between moving
parts, this design is not lubricated. Diaphragm compressors are often selected when no
contamination is allowed in the output air or atmosphere, such as hospital and laboratory
applications. Diaphragm compressors are limited in output and pressure and they are used
most often for light-duty applications.
Figure 13: Diaphragm Type
5- Rotary Sliding Vane Type
The rotary vane compressor consists of a rotor mounted eccentrically in a housing (Figure 14
). As the rotor turns, the vanes slide out by centrifugal force until they seal against a thin film
16
of lubricant coating the stator wall. There is no metal-to-metal contact as the blade tip glides
on the surface of the lubricant. Air compression occurs when the volume of the spaces
between the sliding vanes is reduced as the rotor turns in the eccentric cylinder. Single-stage
rotary vanes are oil injected and are most common in industrial applications ranging in
pressure from 60 psi to 200 psi. Multi-stage versions range in pressure from 60 psi to 150 psi,
use flow-through lubrication that “consumes” lubricant and are most typically used in moving
bulk material i.e., concrete. While there are oil-free rotary vane blowers and vacuum pumps,
rotary vane compressors are not oil free.
Some of the advantages of rotary vane compressors are smooth and pulse-free air output, low
noise, high output volume, low vibrations, prolonged service intervals and long life.
Figure 14: Rotary Sliding Vane Type
6- Rotary Helical Screw Type
Rotary helical screw compressors (Figure 15) utilize two intermeshing helical rotors in a
twin-bore case. In a single-stage design, the air inlet is usually located at the top of the
cylinder
near the drive shaft end. The discharge port is located at the opposite end of the cylinder. As
the rotors unmesh at the air inlet end of the cylinder, air is drawn into the cavity between the
main rotor lobes and the secondary rotor grooves. As rotation continues, the rotor tips pass
the edges of the inlet ports, trapping air in a cell formed by the rotor cavities and the cylinder
wall. Compression begins as further rotation causes the main rotor lobes to roll into the
secondary rotor grooves, reducing the volume and raising cell pressure.
Oil is injected after cell closing to seal clearances and remove heat of compression.
Compression continues until the rotor tips pass the discharge porting and release of the
compressed air and oil mixture is obtained. Single or multi-stage versions are available. This
type of compressor can be oil lubricated, water lubricated or oil-free. Some advantages of the
of lubricant coating the stator wall. There is no metal-to-metal contact as the blade tip glides
on the surface of the lubricant. Air compression occurs when the volume of the spaces
between the sliding vanes is reduced as the rotor turns in the eccentric cylinder. Single-stage
rotary vanes are oil injected and are most common in industrial applications ranging in
pressure from 60 psi to 200 psi. Multi-stage versions range in pressure from 60 psi to 150 psi,
use flow-through lubrication that “consumes” lubricant and are most typically used in moving
bulk material i.e., concrete. While there are oil-free rotary vane blowers and vacuum pumps,
rotary vane compressors are not oil free.
Some of the advantages of rotary vane compressors are smooth and pulse-free air output, low
noise, high output volume, low vibrations, prolonged service intervals and long life.
Figure 14: Rotary Sliding Vane Type
6- Rotary Helical Screw Type
Rotary helical screw compressors (Figure 15) utilize two intermeshing helical rotors in a
twin-bore case. In a single-stage design, the air inlet is usually located at the top of the
cylinder
near the drive shaft end. The discharge port is located at the opposite end of the cylinder. As
the rotors unmesh at the air inlet end of the cylinder, air is drawn into the cavity between the
main rotor lobes and the secondary rotor grooves. As rotation continues, the rotor tips pass
the edges of the inlet ports, trapping air in a cell formed by the rotor cavities and the cylinder
wall. Compression begins as further rotation causes the main rotor lobes to roll into the
secondary rotor grooves, reducing the volume and raising cell pressure.
Oil is injected after cell closing to seal clearances and remove heat of compression.
Compression continues until the rotor tips pass the discharge porting and release of the
compressed air and oil mixture is obtained. Single or multi-stage versions are available. This
type of compressor can be oil lubricated, water lubricated or oil-free. Some advantages of the
17
rotary helical screw compressors are smooth and pulse-free air output, compact size, high
output volume, low vibrations, prolonged service intervals and long life.
Figure 15: Rotary Helical Screw Type
7- Rotary Scroll Type
element that progressively compresses inlet air (Figure 16). This process is continuously
repeated, resulting in the delivery of pulsation-free compressed air. With fewer moving parts,
reduced maintenance becomes an operating advantage. Scroll compressors can be of
lubricated or oil- Air compression within a scroll is accomplished by the interaction of a fixed
and an orbiting helical free design.
Figure 16: Rotary Scroll Type
CRANK SHAFT
For conversion between reciprocating motion and rotational motion the crankshaft,
sometimes also abbreviated to crank, is mainly responsible for motion. In a reciprocating
engine, it translates reciprocating linear piston motion into rotational motion, whereas in a
reciprocating compressor, it converts the rotational motion into reciprocating motion. In
order to complete conversion between these two motions, the crankshaft consists of "crank
throws" or "crank pins", additional bearing surfaces whose axis is offset from that of the
crank, to which the "big ends" of the connecting rods from each cylinder attach. To reduce
the pulsation characteristic of the four-stroke cycle It is typically connected to a flywheel ,
and sometimes a torsional or vibrational damper at the opposite end, to reduce the torsional
vibrations often caused along the length of the crankshaft by the cylinders farthest from the
output end acting on the torsional elasticity of the metal
[7]
.
rotary helical screw compressors are smooth and pulse-free air output, compact size, high
output volume, low vibrations, prolonged service intervals and long life.
Figure 15: Rotary Helical Screw Type
7- Rotary Scroll Type
element that progressively compresses inlet air (Figure 16). This process is continuously
repeated, resulting in the delivery of pulsation-free compressed air. With fewer moving parts,
reduced maintenance becomes an operating advantage. Scroll compressors can be of
lubricated or oil- Air compression within a scroll is accomplished by the interaction of a fixed
and an orbiting helical free design.
Figure 16: Rotary Scroll Type
CRANK SHAFT
For conversion between reciprocating motion and rotational motion the crankshaft,
sometimes also abbreviated to crank, is mainly responsible for motion. In a reciprocating
engine, it translates reciprocating linear piston motion into rotational motion, whereas in a
reciprocating compressor, it converts the rotational motion into reciprocating motion. In
order to complete conversion between these two motions, the crankshaft consists of "crank
throws" or "crank pins", additional bearing surfaces whose axis is offset from that of the
crank, to which the "big ends" of the connecting rods from each cylinder attach. To reduce
the pulsation characteristic of the four-stroke cycle It is typically connected to a flywheel ,
and sometimes a torsional or vibrational damper at the opposite end, to reduce the torsional
vibrations often caused along the length of the crankshaft by the cylinders farthest from the
output end acting on the torsional elasticity of the metal
[7]
.
18
CHAPTER-4 FUTURE ASPECTS
TEST APPARATUS
The proposed test apparatus consists of a compressed air storage tank with an inlet, outlet
and drain valve. The storage tank is mounted on a movable skid for testing different
compressed air usage points. The test apparatus is installed with pressure gauges and a
temperature gauge. The drain valve installed is used for removing the mois- ture from the
storage tank. The construction detail of the test apparatus is provided in Figure 1. The
reduction of pressure and the operating temperature of compressed air in the storage tank are
the main parameters measured during the operation of the test apparatus. The test appa-ratus
is used for estimation of air flow based on reduction of compressed air pressure in the storage
tank (of known volume) in a given time. The principle used considers air as an ideal gas with
unsteady flow from the storage tankgiven in Equation (5)
ma= (Pi-Pf)V/(RTt) (5)
where, ma is actual mass flow rate of air in kg/s; Pi is initial pressure in kPa; Pf is final
pressure in kPa; t is time in s; R is characteristic gas constant for air in kJ/kg K; T is
temperature in K. The test apparatus is connected to the end-use point through a flexible pipe
after a valve V1, shown in Figure 17. The air is supplied to the storage tank from a com
pressed air header using a valve V2. After the storage tank is filled to the level of the
compressed air header pressure monitored with the help of a pressure gauge P1, the valve
V2 is closed to isolate the header from the storage tank. The moisture in the storage tank is
drained with help of a valve V3. The valve V1 is adjusted to set the required pressure of end-
use point with the help of a pressure gauge P2.
The compressed air is used for application after re-cording of initial pressure of the storage
tank using the pressure gauge P1 and a temperature sensor T1. The time taken for pressure
reduction in the pressure gauge P1 is monitored with help of a stop watch. The reduction in
pressure and time required for the pressure reduction is used for estimation of mass flow rate
with the help of Equation (5)
Some of the advantages of the test apparatus are
Low cost compared to compressed air mass flow me-ter;
Easy and accurate measurement of small quantity of flow rates;
Simple to operate in an industrial environment similar to compressor pump-up test;
No need of special calibration, standard calibrated pressure and temperature sensors
can be used;
Does not create any pressure drop in the system;
Limitations of test apparatus developed;
Cannot be installed for online measurement;
Size and weight of system is more as compared to mass flow meters;
Manual intervention required for operation and ob-servations.
The test apparatus developed can be used for the quan-tification of compressed air flow for
an end-use equip- ment. The quantification of flow can be used as a bench- mark of
performance and any increase in the compressed air flow compared to benchmark reflects
performance de- terioration. The quantification of performance deteriora- tion will be helpful
for taking corrective actions to re- store the performance
[8]
.
CHAPTER-4 FUTURE ASPECTS
TEST APPARATUS
The proposed test apparatus consists of a compressed air storage tank with an inlet, outlet
and drain valve. The storage tank is mounted on a movable skid for testing different
compressed air usage points. The test apparatus is installed with pressure gauges and a
temperature gauge. The drain valve installed is used for removing the mois- ture from the
storage tank. The construction detail of the test apparatus is provided in Figure 1. The
reduction of pressure and the operating temperature of compressed air in the storage tank are
the main parameters measured during the operation of the test apparatus. The test appa-ratus
is used for estimation of air flow based on reduction of compressed air pressure in the storage
tank (of known volume) in a given time. The principle used considers air as an ideal gas with
unsteady flow from the storage tankgiven in Equation (5)
ma= (Pi-Pf)V/(RTt) (5)
where, ma is actual mass flow rate of air in kg/s; Pi is initial pressure in kPa; Pf is final
pressure in kPa; t is time in s; R is characteristic gas constant for air in kJ/kg K; T is
temperature in K. The test apparatus is connected to the end-use point through a flexible pipe
after a valve V1, shown in Figure 17. The air is supplied to the storage tank from a com
pressed air header using a valve V2. After the storage tank is filled to the level of the
compressed air header pressure monitored with the help of a pressure gauge P1, the valve
V2 is closed to isolate the header from the storage tank. The moisture in the storage tank is
drained with help of a valve V3. The valve V1 is adjusted to set the required pressure of end-
use point with the help of a pressure gauge P2.
The compressed air is used for application after re-cording of initial pressure of the storage
tank using the pressure gauge P1 and a temperature sensor T1. The time taken for pressure
reduction in the pressure gauge P1 is monitored with help of a stop watch. The reduction in
pressure and time required for the pressure reduction is used for estimation of mass flow rate
with the help of Equation (5)
Some of the advantages of the test apparatus are
Low cost compared to compressed air mass flow me-ter;
Easy and accurate measurement of small quantity of flow rates;
Simple to operate in an industrial environment similar to compressor pump-up test;
No need of special calibration, standard calibrated pressure and temperature sensors
can be used;
Does not create any pressure drop in the system;
Limitations of test apparatus developed;
Cannot be installed for online measurement;
Size and weight of system is more as compared to mass flow meters;
Manual intervention required for operation and ob-servations.
The test apparatus developed can be used for the quan-tification of compressed air flow for
an end-use equip- ment. The quantification of flow can be used as a bench- mark of
performance and any increase in the compressed air flow compared to benchmark reflects
performance de- terioration. The quantification of performance deteriora- tion will be helpful
for taking corrective actions to re- store the performance
[8]
.
19
Figure 17: Experimental setup for characterization of blow gun
ADVANTAGES
The principal advantages of an Air compressed engine is-
It uses no gasoline or other bio-carbon based fuel.
Refueling may be done at home, but filling the tanks to full pressure would require
compressors for 250-300 bars, which are not normally available for home standard
utilization, considering the danger inherent at these pressure levels. As with gasoline,
service stations would have to install the necessary air facilities if such cars became
sufficiently popular to warrant it.
Compressed air engines reduce the cost of vehicle production, because there is no
need to build a cooling system, spark plugs, starter motor.
The rate of self-discharge is very low opposed to batteries that deplete their charge
slowly over time. Therefore, the vehicle may be left unused for longer periods of time
than electric cars.
Expansion of the compressed air lowers its temperature; this may be exploited for use
as air conditioning.
Reduction or elimination of hazardous chemicals such as gasoline or battery
acids/metals.
Some mechanical configurations may allow energy recovery during braking by
compressing and storing air
[9]
.
The engine can be massively reduced in size.
Figure 17: Experimental setup for characterization of blow gun
ADVANTAGES
The principal advantages of an Air compressed engine is-
It uses no gasoline or other bio-carbon based fuel.
Refueling may be done at home, but filling the tanks to full pressure would require
compressors for 250-300 bars, which are not normally available for home standard
utilization, considering the danger inherent at these pressure levels. As with gasoline,
service stations would have to install the necessary air facilities if such cars became
sufficiently popular to warrant it.
Compressed air engines reduce the cost of vehicle production, because there is no
need to build a cooling system, spark plugs, starter motor.
The rate of self-discharge is very low opposed to batteries that deplete their charge
slowly over time. Therefore, the vehicle may be left unused for longer periods of time
than electric cars.
Expansion of the compressed air lowers its temperature; this may be exploited for use
as air conditioning.
Reduction or elimination of hazardous chemicals such as gasoline or battery
acids/metals.
Some mechanical configurations may allow energy recovery during braking by
compressing and storing air
[9]
.
The engine can be massively reduced in size.
20
The engine runs on cold or warm air, so can be made of lower strength light weight
material such as aluminium, plastic, low friction teflon or a combination.
DISADVANTAGES
The principal disadvantages are the additional steps of energy conversion and transmission,
because each inherently has loss. For combustion engine cars, the energy is lost when
chemical energy in fossil fuels is converted by the engine to mechanical energy. For electric
cars, a power plant's electricity (from whatever source) is transmitted to the car's batteries,
which then transmits the electricity to the car's motor, which converts it to mechanical
energy. For compressed-air cars, the power plant's electricity is transmitted to a compressor,
which mechanically compresses the air into the car's tank. The car's engine then converts the
compressed air to mechanical energy.
Additional concerns:
When air expands, as it would in the engine, it cools dramatically (Charles's law) and
must be heated to ambient temperature using a heat exchanger similar to
the Intercooler used for internal combustion engines. The heating is necessary in order
to obtain a significant fraction of the theoretical energy output. The heat exchanger
can be problematic. While it performs a similar task to the Intercooler, the
temperature difference between the incoming air and the working gas is smaller. In
heating the stored air, the device gets very cold and may ice up in cool, moist
climates.
Refueling the compressed-air container using a home or low-end conventional air
compressor may take as long as 4 hours, while the specialized equipment at service
stations may fill the tanks in only 3 minutes.
Conversely, when air is compressed to fill the tank, its temperature increases. If the
stored air is not cooled while the tank is being filled, then when the air cools off later,
its pressure decreases and the available energy decreases.
Limited capacity of storage tanks.
Limited speed range (110-140 Km)
[10]
.
AIR COMPRESSED ENGINE IN INDIA
Tata Motors has signed an agreement with Motor Development Internationalof France to
develop a car that runs oncompressed air, thus making it veryeconomical to run and almost
totallypollution free. Although there is no officialword on when the car will be
commerciallymanufactured for India, reportssay that it will be sooner than later.The car -
MiniCAT - could cost aroundRs 350,000 in India and would have arange of around 300 km
between refuels.The cost of a refill would be aboutRs 90. In the single energy mode MDI
cars consume around Rs 45 every 100km. Figure 18 shows the proposed air car for India.
The smallest and most innovative(three seats, minimal dimensionswith the boot of a saloon),
it is agreat challenge for such a small carwhich runs on compressed air. TheMiniCAT is the
city car of the future.
The engine runs on cold or warm air, so can be made of lower strength light weight
material such as aluminium, plastic, low friction teflon or a combination.
DISADVANTAGES
The principal disadvantages are the additional steps of energy conversion and transmission,
because each inherently has loss. For combustion engine cars, the energy is lost when
chemical energy in fossil fuels is converted by the engine to mechanical energy. For electric
cars, a power plant's electricity (from whatever source) is transmitted to the car's batteries,
which then transmits the electricity to the car's motor, which converts it to mechanical
energy. For compressed-air cars, the power plant's electricity is transmitted to a compressor,
which mechanically compresses the air into the car's tank. The car's engine then converts the
compressed air to mechanical energy.
Additional concerns:
When air expands, as it would in the engine, it cools dramatically (Charles's law) and
must be heated to ambient temperature using a heat exchanger similar to
the Intercooler used for internal combustion engines. The heating is necessary in order
to obtain a significant fraction of the theoretical energy output. The heat exchanger
can be problematic. While it performs a similar task to the Intercooler, the
temperature difference between the incoming air and the working gas is smaller. In
heating the stored air, the device gets very cold and may ice up in cool, moist
climates.
Refueling the compressed-air container using a home or low-end conventional air
compressor may take as long as 4 hours, while the specialized equipment at service
stations may fill the tanks in only 3 minutes.
Conversely, when air is compressed to fill the tank, its temperature increases. If the
stored air is not cooled while the tank is being filled, then when the air cools off later,
its pressure decreases and the available energy decreases.
Limited capacity of storage tanks.
Limited speed range (110-140 Km)
[10]
.
AIR COMPRESSED ENGINE IN INDIA
Tata Motors has signed an agreement with Motor Development Internationalof France to
develop a car that runs oncompressed air, thus making it veryeconomical to run and almost
totallypollution free. Although there is no officialword on when the car will be
commerciallymanufactured for India, reportssay that it will be sooner than later.The car -
MiniCAT - could cost aroundRs 350,000 in India and would have arange of around 300 km
between refuels.The cost of a refill would be aboutRs 90. In the single energy mode MDI
cars consume around Rs 45 every 100km. Figure 18 shows the proposed air car for India.
The smallest and most innovative(three seats, minimal dimensionswith the boot of a saloon),
it is agreat challenge for such a small carwhich runs on compressed air. TheMiniCAT is the
city car of the future.
21
Figure 18: Compressed air car for India
OTHER DEVELOPMENT IN COMPRESSED AIR TECHNOLOGY
Currently some new technologies regardingcompressed air cars haveemerged. A Republic of
Korean companyhas created a pneumatic hybridelectric vehicle car engine that runs on
electricity and compressed air. The engine,which powers a pneumatic-hybridelectric vehicle
(PHEV), worksalongside an electric motor to createthe power source. The system
eliminatesthe need for fuel, making thePHEV pollution-free. The system is controlledby an
ECU in the car, which controlsboth power packs i.e. the compressed-air engine and electric
motor.The compressed air drives the pistons,which turn the vehicle’s wheels. The airis
compressed, using a small motor,powered by a 48-volt battery, whichpowers both the air
compressor andthe electric motor. Once compressed,the air is stored in a tank. The
compressedair is used when the car needsa lot of energy, such as for starting upand
acceleration. The electric motorcomes to life once the car has gainednormal cruising speed.
The PHEV systemcould reduce the cost of vehicleproduction by about 20 per cent, because
there is no need for a coolingsystem, fuel tank, spark plugs or silencers.Figure 7 shows the
PHEV in theRepublic of Korea
[11]
.
Figure 19: PHEV in Republic of Korea
Figure 18: Compressed air car for India
OTHER DEVELOPMENT IN COMPRESSED AIR TECHNOLOGY
Currently some new technologies regardingcompressed air cars haveemerged. A Republic of
Korean companyhas created a pneumatic hybridelectric vehicle car engine that runs on
electricity and compressed air. The engine,which powers a pneumatic-hybridelectric vehicle
(PHEV), worksalongside an electric motor to createthe power source. The system
eliminatesthe need for fuel, making thePHEV pollution-free. The system is controlledby an
ECU in the car, which controlsboth power packs i.e. the compressed-air engine and electric
motor.The compressed air drives the pistons,which turn the vehicle’s wheels. The airis
compressed, using a small motor,powered by a 48-volt battery, whichpowers both the air
compressor andthe electric motor. Once compressed,the air is stored in a tank. The
compressedair is used when the car needsa lot of energy, such as for starting upand
acceleration. The electric motorcomes to life once the car has gainednormal cruising speed.
The PHEV systemcould reduce the cost of vehicleproduction by about 20 per cent, because
there is no need for a coolingsystem, fuel tank, spark plugs or silencers.Figure 7 shows the
PHEV in theRepublic of Korea
[11]
.
Figure 19: PHEV in Republic of Korea
22
CONCLUSION
Nowadays the need for energy continuously increases, and we are using the conventional
resources at an alarming rate hence an alternative fuel is much required and Compressed Air
Technology can be one of the best alternative, as the pollution caused is zero and it is also
cost efficient. After ten years of research and development, the compressed air vehicle will be
introduced worldwide. Since Compressed Air Technology(CAT) isbest technology which
tend engine to zero pollutions and through this we can power our cars, ships, train anything
except aeroplane. If further improvement is carried out with stress analysis, thermodynamic
analysis, minimize compressed energy loss and other losses then efficiency of CAE may be
further increases.After that we get every answers which we expect from our Environment as
like, By this technology its possible to solve the environment problem what we’re facing
today? Of course we can! We can do anything and everything what we want. Now We have
been to the moon. We also have been into space. If we have damaged something whatever it
should be now easily it should be fixed up
[12]
.
CONCLUSION
Nowadays the need for energy continuously increases, and we are using the conventional
resources at an alarming rate hence an alternative fuel is much required and Compressed Air
Technology can be one of the best alternative, as the pollution caused is zero and it is also
cost efficient. After ten years of research and development, the compressed air vehicle will be
introduced worldwide. Since Compressed Air Technology(CAT) isbest technology which
tend engine to zero pollutions and through this we can power our cars, ships, train anything
except aeroplane. If further improvement is carried out with stress analysis, thermodynamic
analysis, minimize compressed energy loss and other losses then efficiency of CAE may be
further increases.After that we get every answers which we expect from our Environment as
like, By this technology its possible to solve the environment problem what we’re facing
today? Of course we can! We can do anything and everything what we want. Now We have
been to the moon. We also have been into space. If we have damaged something whatever it
should be now easily it should be fixed up
[12]
.
23
REFERENCES
[1] Gairns J F 1904. Industrial locomotives for mining, factory, and allied uses. Part II.
Compressed air and internal combustion locomotives Cassier's Mag. 16363-77.
[2] SAE 1999-01-0623, Schechter.M., “New Cycles for Automobile engines.
[3] ISSN: 2456-1843, STUDY AND FABRICATION OF COMPRESSED AIR ENGINE
Ruby Sharma ,Naveen Singla, vol.1, January 2015, pp:27.
[4] HE Wei et al. “Performance study on three-stage power system of compressed air vehicle
based on single-screw expander” science china, technological sciences, August 2010,
pp:2299–2303.
[5] Shen, Y.T. and Hwang, Y.R. (2009) Design and Implementation of an Air-Powered
Motorcycles. Applied Energy, 86, 1105-
1110.http://dx.doi.org/10.1016/j.apenergy.2008.06.008
[6] Huang, C.H., Hu, C.K., Yu, C.J., et al. (2013) Experimental Investigation on the
Performance of a Compressed-AirDriven Piston Engine. Energies, 6, 1731-1745.
http://dx.doi.org/10.3390/en6031731
[7] Cai, M.L., Kawashima, K. and Kagawa, T. (2006) Power Assessment of Flowing
Compressed Air. Journal of FluidsEngineering, 128, 402-405.
http://dx.doi.org/10.1115/1.2170129
[8] R. N. James and J. J. K. Peter, “Compressed Air System Best Practice Programmer: What
Needs to Change to Se- cure Long-Term Energy Savings for New Zealand,” En- ergy Policy,
Vol. 37, No. 9, 2009, pp. 3400-3408. doi:10.1016/j.enpol.2009.04.047
[9] Matt Campbell (November 3, 2011). "The motorbike that runs on air". Sydney Morning
Herald. Retrieved 2011-11-07.
[10] "Bosch Rexroth Named Subcontractor for Hydraulic Hybrid Refuse Truck Field
Test" (Press release). Bosch Rexroth Corporation. May 16, 2007. RetrievedJune 15, 2012.
[11] Tokhi, M.O., Al-Miskiry, M. and Brisland, M. (2001) Real Time Control of Air Motors
Using a Pneumatic H-Bridge.Control Engineering Practice, 9, 449-457.
http://dx.doi.org/10.1016/S0967-0661(00)00122-2
[12] Amir Fazeli et al. “A novel compression strategy forair hybrid engines” Applied Energy
88 (2011) ,8March 2011,pp:2955–2966
REFERENCES
[1] Gairns J F 1904. Industrial locomotives for mining, factory, and allied uses. Part II.
Compressed air and internal combustion locomotives Cassier's Mag. 16363-77.
[2] SAE 1999-01-0623, Schechter.M., “New Cycles for Automobile engines.
[3] ISSN: 2456-1843, STUDY AND FABRICATION OF COMPRESSED AIR ENGINE
Ruby Sharma ,Naveen Singla, vol.1, January 2015, pp:27.
[4] HE Wei et al. “Performance study on three-stage power system of compressed air vehicle
based on single-screw expander” science china, technological sciences, August 2010,
pp:2299–2303.
[5] Shen, Y.T. and Hwang, Y.R. (2009) Design and Implementation of an Air-Powered
Motorcycles. Applied Energy, 86, 1105-
1110.http://dx.doi.org/10.1016/j.apenergy.2008.06.008
[6] Huang, C.H., Hu, C.K., Yu, C.J., et al. (2013) Experimental Investigation on the
Performance of a Compressed-AirDriven Piston Engine. Energies, 6, 1731-1745.
http://dx.doi.org/10.3390/en6031731
[7] Cai, M.L., Kawashima, K. and Kagawa, T. (2006) Power Assessment of Flowing
Compressed Air. Journal of FluidsEngineering, 128, 402-405.
http://dx.doi.org/10.1115/1.2170129
[8] R. N. James and J. J. K. Peter, “Compressed Air System Best Practice Programmer: What
Needs to Change to Se- cure Long-Term Energy Savings for New Zealand,” En- ergy Policy,
Vol. 37, No. 9, 2009, pp. 3400-3408. doi:10.1016/j.enpol.2009.04.047
[9] Matt Campbell (November 3, 2011). "The motorbike that runs on air". Sydney Morning
Herald. Retrieved 2011-11-07.
[10] "Bosch Rexroth Named Subcontractor for Hydraulic Hybrid Refuse Truck Field
Test" (Press release). Bosch Rexroth Corporation. May 16, 2007. RetrievedJune 15, 2012.
[11] Tokhi, M.O., Al-Miskiry, M. and Brisland, M. (2001) Real Time Control of Air Motors
Using a Pneumatic H-Bridge.Control Engineering Practice, 9, 449-457.
http://dx.doi.org/10.1016/S0967-0661(00)00122-2
[12] Amir Fazeli et al. “A novel compression strategy forair hybrid engines” Applied Energy
88 (2011) ,8March 2011,pp:2955–2966
24
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