COIN BOX BASED

AUTOMATIC WHEEL
AIR FILLING SYSTEM
CONTENTS
 CONTENTS

CHAPTER NO TITLE

SYNOPSIS
LIST OF FIGURES
NOMENCLATURE
1 Introduction
2 Literature review
3 Description of equipments
3.1 Compressor
3.2 Valves
3.3 Hoses
3.4 Power supply
3.5 Microcontroller
4 Design and drawing
4.1 Pneumatic components and Specification
4.2 Design calculation
5 Working principle
6 Merits and demerits
7 Applications
8 List of materials
9 Cost Estimation
10 Conclusion
Bibliography
photography
LIST OF FIGURES
 LIST OF FIGURES

Figure
Number Title

1 Solenoid valve
2 Hose
3 Overall Diagram
NOMENCLATURE
 NOMENCLATURE

 A =Area of cylinder(m2 )

 D=Diameter of Piston (m)

 F =Force exerted on the piston (N)

 H=Height (m)

 L=Length(m)

 P=Pressure (N/m2)

 V=Volume (m3)
SYNOPSIS
 SYNOPSIS

Our project is microcontroller based coin box for paying the amount to a
air filling system. This project will be very much useful to car owners and
vulcanizing owners. This project is fully automated one. The air will be fill by
the wheel according to the money paid by the car owners. The time consumed
by filling the air is very less when compared to manual air filling system.
 CHAPTER-1
INTRODUCTION
 CHAPTER – 1

INTRODUCTION

The car owners are deposit the money to the coin box. The
microcontroller unit senses the coin and gives the output signal to the air filling
system according to the money pay by the car owners. The solenoid valve is
used to deliver the air from the tank and deliver to the cars or two wheelers
wheels.
 CHAPTER-2

LITERATURE SURVAY
 CHAPTER-2

LITERATURE SURVEY

Solenoid valves:
A solenoid valve is an electromechanically operated 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.
Besides the plunger-type actuator which is used most frequently, pivoted-
armature actuators and rocker actuators are also used.
Operation
A solenoid valve has two main parts: the solenoid and the valve. The
solenoid converts electrical energy into mechanical energy which, in turn, opens
or closes the valve mechanically. A direct acting valve has only a small flow
circuit, shown within section E of this diagram (this section is mentioned below
as a pilot valve). In this example, adiaphragm piloted valve multiplies this small
pilot flow, by using it to control the flow through a much larger orifice.
Solenoid valves may use metal seals or rubber seals, and may also have
electrical interfaces to allow for easy control. A spring may be used to hold the
valve opened (normally open) or closed (normally closed) while the valve is not
activated.
A- Input side
B- Diaphragm
C- Pressure chamber
D- Pressure relief passage
E- Solenoid
F- Output side
The diagram to the right shows the design of a basic valve, controlling the
flow of water in this example. At the top figure is the valve in its closed state.
The water under pressure enters at A. B is an elastic diaphragm and above it is a
weak spring pushing it down. The function of this spring is irrelevant for now as
the valve would stay closed even without it. The diaphragm has a pinhole
through its center which allows a very small amount of water to flow through it.
This water fills the cavity C on the other side of the diaphragm so that pressure
is equal on both sides of the diaphragm, however the compressed spring
supplies a net downward force. The spring is weak and is only able to close the
inlet because water pressure is equalized on both sides of the diaphragm.
In the previous configuration the small passage D was blocked by a pin which is
the armature of the solenoid Eand which is pushed down by a spring. If the
solenoid is activated by drawing the pin upwards via magnetic force from the
solenoid current, the water in chamber C will flow through this passage D to the
output side of the valve. The pressure in chamber C will drop and the incoming
pressure will lift the diaphragm thus opening the main valve. Water now flows
directly from A to F.
When the solenoid is again deactivated and the passage D is closed again,
the spring needs very little force to push the diaphragm down again and the
main valve closes. In practice there is often no separate spring, the elastomer
diaphragm is molded so that it functions as its own spring, preferring to be in
the closed shape.
From this explanation it can be seen that this type of valve relies on a
differential of pressure between input and output as the pressure at the input
must always be greater than the pressure at the output for it to work. Should the
pressure at the output, for any reason, rise above that of the input then the valve
would open regardless of the state of the solenoid and pilot valve.
In some solenoid valves the solenoid acts directly on the main valve. Others use
a small, complete solenoid valve, known as a pilot, to actuate a larger valve.
While the second type is actually a solenoid valve combined with a
pneumatically actuated valve, they are sold and packaged as a single unit
referred to as a solenoid valve. Piloted valves require much less power to
control, but they are noticeably slower. Piloted solenoids usually need full
power at all times to open and stay open, where a direct acting solenoid may
only need full power for a short period of time to open it, and only low power to
hold it.
Production

Solenoid valves are often mass produced in 3 main parts: the core tube,
the nucleo and the coil.

deep drawn Core Tube made by Pressteck (Italy)

The core tube[1] is a metal shell that is produced by deep drawing because this
process requires considerably less raw material and permits complex designs
that integrate solutions (example O-ring seats, formed flanges and closed tube
ends ) which reduce the amount of parts per valve .
The nucleo is typically a turned metal part, that slides within the core tube,
opening or closing the valve. Its' initial position is normally maintained by a
spring.
The coil is a tightly bound copper wire which is wrapped around the core tube
and induces the movement of the nucleo.
Types
Many variations are possible on the basic, one way, one solenoid valve
described above:
• one or two solenoid valves;
• direct current or alternating current powered;
• different number of ways and positions;
Common uses
Solenoid valves are used in fluid power pneumatic and hydraulic systems,
to control cylinders, fluid power motors or larger industrial valves. Automatic
irrigation sprinkler systems also use solenoid valves with an automatic
controller. Domestic washing machines and dishwashers use solenoid valves to
control water entry into the machine. Solenoid valves are used in dentist chairs
to control air and water flow. In the paintball industry, solenoid valves are
usually referred to simply as "solenoids." They are commonly used to control a
larger valve used to control the propellant (usually compressed air or CO2). In
addition to this, these valves are now been used in household water purifiers
(RO systems).
Besides controlling the flow of air and fluids, solenoids are used in
pharmacology experiments, especially for patch-clamp, which can control the
application of agonist or antagonist.[2]
 CHAPTER-3

DESCRIPTION OF EQUIPMENT
 CHAPTER-3

DESCRIPTION OF EQUIPMENT

3.1 COMPRESSOR

A gas compressor is a mechanical device that increases the

pressure of a gas by reducing its volume. Compressors are similar to pumps:

both 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, so the main action of a pump is to

transport liquids.

The key part of any facility for supply of compressed air is by means using

reciprocating compressor. A compressor is a machine that takes in air, gas at a

certain pressure and delivered the air at a high pressure.

Compressor capacity is the actual quantity of air compressed and

delivered and the volume expressed is that of that of the air at intake conditions

namely at atmosphere pressure and normal ambient temperature.

Clean condition of the suction air is one of the factors, which decides the

life of a compressor. Warm and moist suction air will result increased

precipitation of condense from the compressed air.

Compressor may be classified in two general types.

1. Positive displacement compressor

2. Turbo compressor
Positive displacement compressors are most frequently employed for

Compressed air plant and have proved highly successful and supply air for

pneumatic control application.

The types of positive compressor

1. Reciprocating type compressor

2. Rotary type compressor

Turbo compressors are employed where large of air required at low

discharge pressures. They cannot attain pressure necessary for pneumatic

control application unless built in multistage designs and are seldom

encountered in pneumatic service.

RECIPROCATING COMPRESSORS:

Built for either stationary (or) portable service the reciprocating

compressor is by far the most common type. Reciprocating compressors lap be

had is sizes from the smallest capacities to deliver more than 500m3/min.In

single stage compressor, the air pressure may be of 6 bar machines discharge of

pressure is up to 15bars.Discharge pressure in the range of 250bars can be

obtained with high pressure reciprocating compressors that of three & four

stages. Single stage and 1200 stage models are particularly suitable

For applications, with preference going to the two stage design as soon as

the discharge pressure exceeds 6 bars, because it in capable of matching the

performance of single stage machine at lower costs per driving powers in the

range.
 The compressibility of the air was first investigated by Robot Boyle in

1962 and that found that the product of pressure and volumes of particular

quantity of gas.

The usual written as

PV =C (or) P1V1 =P2V2

In this equation the pressure is the absolute pressured which for free is

about 14.7Psi and is of courage capable of maintaining a column of mercury,

nearly 30 inches high in an ordinary barometer.

3.2 VALVES

SOLENOID VALVE

The directional valve is one of the important parts of a pneumatic system.

Commonly known as DCV; this valve is used to control the direction of air flow

in the pneumatic system. The directional valve does this by changing the

position of its internal movable parts.

This valve was selected for speedy operation and to reduce the manual

effort and also for the modification of the machine into automatic machine by

means of using a solenoid valve.

A solenoid is an electrical device that converts electrical energy into

straight line motion and force. These are also used to operate a mechanical
operation which in turn operates the valve mechanism. Solenoid is one is which

the plunger is pulled when the solenoid is energized.

The name of the parts of the solenoid should be learned so that they can

be recognized when called upon to make repairs, to do service work or to install

them.
Parts of a solenoid valve

1. Coil

The solenoid coil is made of copper wire. The layers of wire are separated

by insulating layer. The entire solenoid coil is covered with a varnish that is not

affected by solvents, moisture, cutting oil or often fluids. Coils are rated in

various voltages such as 115 volts AC,230volts AC,460volts Ac,575 Volts

AC.6Volts DC,12Volts DC,

24 Volts DC, 115 Volts DC &230Volts DC. They are designed for such

Frequencies as 50Hz to 60Hz.

2. Frame

The solenoid frame serves several purposes. Since it is made of laminated

sheets, it is magnetized when the current passes through the coil. The

magnetized coils attract the metal plunger to move. The frame has provisions

for attaching the mounting. They are usually bolted or welded to the frame. The

frame has provisions for receivers, the plunger. The wear strips are mounted to

the solenoid frame, and are made of materials such as metal or impregnated less

Fiber.

3. Solenoid plunger

The solenoid plunger is the mover mechanism of the solenoid. The

plunger is made of steel laminations which are riveted together under high

pressure, so that there will be no movement of the lamination with respect to

one another. At the top of the plunger a pin hole is placed for making a

connection to some device. The solenoid plunger is moved by a magnetic force

in one direction and is usually returned by spring action.

Solenoid operated valves are usually provided with cover either the

solenoid or the entire valve. This protects the solenoid from dirt and other

foreign matter, and protects the actuator. In many applications it is necessary to

use explosion proof solenoids.

WORKING OF SOLENOID VALVE:

The solenoid valve has 5 openings. These ensure easy exhausting of

5/4Valve.the spool of the 5/4 valve slide inside the main bore according to spool

position: the ports get connected and disconnected.

The working principle is as follows.

Position-1

When the spool is actuated towards outer direction port ‘P’ gets

Connected to ‘B’ and ‘S’ remains closed while ‘A’ gets connected to ‘R’.

Position-2

When the spool is pushed in the inner direction port ‘P’ and ‘A’

Gets connected to each other and ‘B’ to ‘S’ while port ‘R’ remains closed.

SOLINOID VALVE (OR) CUT OFF VALVE:

The control valve is used to control the flow direction is called cut off

valve or solenoid valve. This solenoid cutoff valve is controlled by the

electronic control unit.

In our project separate solenoid valve is used for flow direction of vice

cylinder. It is used to flow the air from compressor to the single acting cylinder.
3.2.2 FLOW CONTROL VALVE:

In any fluid power circuit, flow control valve is used to control the speed

of actuator. The flow control can be achieved by varying the area of flow

through which the air in passing.

When area is increased, more quantity of air will be sent to actuator as a

result its speed will increase. If the quantity of air entering into the actuator is

reduced, the speed of the actuator is reduced.

3.2.3 PRESSURE CONTROL VALVE:

The main function of the pressure control valve is to limit (or) Control the

pressure required in a pneumatic circuit. Depending upon the method of

controlling they are classified as

1. Pressure relief valve

2. Pressure reducing valve

3.3. HOSES:

Hoses used in this pneumatic system are made up of polyurethane. These

hose can with stand at a maximum pressure level of 10N/m2 .

Connectors:

In our system there are two type of connectors used. One is the Hose

connector and the other is the reducer. Hose connectors normally comprise an

adopt hose nipple and cap nut. These types of connectors are made up of brass

(or) aluminum (or) hardened pneumatic steel.

3.4 POWER SUPPLY

Power supply is a reference to a source of electrical power. A device or

system that supplies electrical or other types of energy to an output load or
group of loads is called a power supply unit. The term is most commonly
applied to electrical energy supplies, less often to mechanical ones, and rarely to
others.

This typically involves converting 240 volt AC supplied by a utility

company to a well-regulated lower voltage (+/-12V) DC for electronic devices.

The ac voltage, typically 220V rms, is connected to a transformer, which

steps that ac voltage down to the level of the desired dc output. A diode rectifier
then provides a full-wave rectified voltage that is initially filtered by a simple
capacitor filter to produce a dc voltage. This resulting dc voltage usually has
some ripple or ac voltage variation.

A regulator circuit removes the ripples and also remains the same dc
value even if the input dc voltage varies, or the load connected to the output dc
voltage changes. This voltage regulation is usually obtained using one of the
popular voltage regulator IC units.

Working principle

Transformer

The potential transformer will step down the power supply voltage (0-
230V) to (0-6V) level. Then the secondary of the potential transformer will be
connected to the precision rectifier, which is constructed with the help of op–
amp. The advantages of using precision rectifier are it will give peak voltage
output as DC, rest of the circuits will give only RMS output.

Bridge rectifier

When four diodes are connected as shown in figure, the circuit is called
as bridge rectifier. The input to the circuit is applied to the diagonally opposite
corners of the network, and the output is taken from the remaining two corners.
 Let us assume that the transformer is working properly and there is a
positive potential, at point A and a negative potential at point B. the positive
potential at point A will forward bias D3 and reverse bias D4.

The negative potential at point B will forward bias D1 and reverse D2. At
this time D3 and D1 are forward biased and will allow current flow to pass
through them; D4 and D2 are reverse biased and will block current flow.

The path for current flow is from point B through D1, up through RL,
through D3, through the secondary of the transformer back to point B. this path
is indicated by the solid arrows. Waveforms (1) and (2) can be observed across
D1 and D3.

One-half cycle later the polarity across the secondary of the transformer
reverse, forward biasing D2 and D4 and reverse biasing D1 and D3. Current
flow will now be from point A through D4, up through RL, through D2, through
the secondary of T1, and back to point A. This path is indicated by the broken
arrows. Waveforms (3) and (4) can be observed across D2 and D4. The current
flow through RL is always in the same direction. In flowing through RL this
current develops a voltage corresponding to that shown waveform (5). Since
current flows through the load (RL) during both half cycles of the applied
voltage, this bridge rectifier is a full-wave rectifier.

One advantage of a bridge rectifier over a conventional full-wave rectifier

is that with a given transformer the bridge rectifier produces a voltage output
that is nearly twice that of the conventional full-wave circuit.

This may be shown by assigning values to some of the components

shown in views A and B. assume that the same transformer is used in both
circuits. The peak voltage developed between points X and y is 1000 volts in
both circuits. In the conventional full-wave circuit shown—in view A, the peak
voltage from the center tap to either X or Y is 500 volts. Since only one diode
can conduct at any instant, the maximum voltage that can be rectified at any
instant is 500 volts.

The maximum voltage that appears across the load resistor is nearly-but
never exceeds-500 v0lts, as result of the small voltage drop across the diode. In
the bridge rectifier shown in view B, the maximum voltage that can be rectified
is the full secondary voltage, which is 1000 volts. Therefore, the peak output
voltage across the load resistor is nearly 1000 volts. With both circuits using the
same transformer, the bridge rectifier circuit produces a higher output voltage
than the conventional full-wave rectifier circuit.

IC voltage regulators

Voltage regulators comprise a class of widely used ICs. Regulator IC

units contain the circuitry for reference source, comparator amplifier, control
device, and overload protection all in a single IC. IC units provide regulation of
either a fixed positive voltage, a fixed negative voltage, or an adjustably set
voltage. The regulators can be selected for operation with load currents from
hundreds of milli amperes to tens of amperes, corresponding to power ratings
from milli watts to tens of watts.

A fixed three-terminal voltage regulator has an unregulated dc input

voltage, Vi, applied to one input terminal, a regulated dc output voltage, Vo,
from a second terminal, with the third terminal connected to ground.

The series 78 regulators provide fixed positive regulated voltages from 5

to 24 volts. Similarly, the series 79 regulators provide fixed negative regulated
voltages from 5 to 24 volts.
 For ICs, microcontroller, LCD --------- 5 volts
 For alarm circuit, op-amp, relay circuits ---------- 12 volts

3.5 MICRO CONTROLLER

A microconroller is a complete microprocessor system built on a
single IC. Microcontoller were developed to meet a need for
microprocessors to be put into low cost products. Building a complete
microprocessor system on a single chip substaintially reduce the cost of
building simple products, which use the microprocessors power to
implement their function,because tye microprocessor is a natural way to
implement many products. This means the idea of using a microprocessor
for low cost products comes up often. But the typical 8 bit
microprocessor based system, such as one using a Z80 and 8085 is
expensive. Both 8085 and Z80 system need some additional circuits to
make a microprocessing system. Each part there is cost of money. Even
though a product design may requires only very simple system, the parts
needed to make the system as a low cost product.
To solve this problem microprocessor system is implemented with
a single chip microcontroller. This could be called microcomputer,as all
the major parts are in the IC.Most frequently they are called
microcomputer because they are used to perform control functions.
The microcontroller contains full implementaion of a standard
MICROPROCESSOR , ROM, RAM, I/O ,CLOCK,TIMERS and also
SERIAL PORTS. Microcontroller also called “system” on a chip “or
single chip microprocessor system"”or computer on a chip.
A microcontroller is a Computer-On-A-Chip, or ,if you prefer a
single chip computer. Micro suggests that the device is small, and
controller tells you that the devics might be used to conrol objects
processor or events. Another term to describe a microconroller and its
support circuits are often built into, or embedded in the devices they
control.
Today microcontroller are very commonly used in wide variety of
intelligent products. For example most personal computers keyboard and
implemented with a microconroller. It replaces scanning, debounce,
matrix decoding and serial transmission circuits. Many low cost
products, such as toys, electtic drills, microwave ovens, VCR and a host
of other consumer and industrial products are based on microcontrollers.
 CHAPTER-4

DESIGN AND DRAWING

 CHAPTER-4

DESIGN OF EQUIPMENT AND DRAWING

BLOCK DIAGRAM

SOLENOID
MICRO VALVE
COIN BOX CONTRO
LLER
CAR/TWO
WHEELERS
WHEELS
DIAGRAM
 CHAPTER -5

WORKING PRINCIPLE
WORKING PRINCIPAL

The air will be fill by the wheel according to the money paid by the car
owners. The time consumed by filling the air is very less when compared to
manual air filling system. The car owners are deposit the money to the coin box.
The microcontroller unit senses the coin and gives the output signal to the air
filling system according to the money pay by the car owners. The solenoid
valve is used to deliver the air from the tank and deliver to the cars or two
wheelers wheels.
 CHAPTER -6

MERITS AND DEMERITS

 CHAPTER-6

MERITS AND DEMERITS

MERITS

Fully Automated Project, so there is no requirement for manual

They require little maintenance as there are no rotating parts
They can easily installed as they are light and require no foundation
They can work under ordinary atmospheric conditions.
Less time conception by filling the air
Fully automated project

DEMIRTS

Coin is detected by the sensor, same coins to be entered (for example

Rs. 2 or Rs. 5)
 CHAPTER-7

APPLICATIONS
 CHAPTER-7

APPLICATIONS

It is very useful for car owners

All the petrol bunk and vulcanizing shop
 CHAPTER-8

LIST OF MATERIALS
 CHAPTER-8

LIST OF MATERIALS

FACTORS DETERMINING THE CHOICE OF MATERIALS

The various factors which determine the choice of material are discussed
below.
1. PROPERTIES:

The material selected must posses the necessary properties for the

proposed application. The various requirements to be satisfied Can be

weight, surface finish, rigidity, ability to withstand environmental attack

from chemicals, service life, reliability etc.

The following four types of principle properties of materials decisively

affect their selection

a. Physical

b. Mechanical

c. From manufacturing point of view

d. Chemical

The various physical properties concerned are melting point, thermal

Conductivity, specific heat, coefficient of thermal expansion, specific gravity,

electrical conductivity, magnetic purposes etc.

The various Mechanical properties Concerned are strength in tensile,

Compressive shear, bending, torsional and buckling load, fatigue resistance,

impact resistance, eleastic limit, endurance limit, and modulus of elasticity,

hardness, wear resistance and sliding properties. The various properties

concerned from the manufacturing point of view are,

 Cast ability

 Weld ability

 Bribability

 Forge ability

 Merchantability

 Surface properties

 Shrinkage

 Deep drawing etc.

2. MANUFACTURING CASE:

Sometimes the demand for lowest possible manufacturing cost or surface

qualities obtainable by the application of suitable coating substances may

demand the use of special materials.

3. QUALITY REQUIRED:

This generally affects the manufacturing process and ultimately the

material. For example, it would never be desirable to go casting of a less

number of components which can be fabricated much more economically by

welding or hand forging the steel.

4. AVILABILITY OF MATERIAL:

Some materials may be scarce or in short supply.it then becomes

obligatory for the designer to use some other material which though may not be

a perfect substitute for the material designed.the delivery of materials and the

delivery date of product should also be kept in mind.

5. SPACE CONSIDERATION:

Sometimes high strength materials have to be selected because the forces

involved are high and space limitations are there.

6. COST:

As in any other problem, in selection of material the cost of material

plays an important part and should not be ignored.

Some times factors like scrap utilization, appearance, and non-

maintenance of the designed part are involved in the selection of proper

materials.
 CHAPTER-9

COST ESTIMATION
 CHAPTER-9

COST ESTIMATION

1. LABOUR COST:

 Lathe

 Drilling

 Welding,

 Grinding,

 Power hacksaw,

 Gas cutting cost

2. OVERGHEAD CHARGES:

The overhead charges are arrived by”manufacturing cost”

Manufacturing Cost =Material Cost +Labour Cost

Overhead Charges =20%of the manufacturing cost

3.TOTAL COST:

Total cost = Material Cost +Labour Cost +Overhead Charges

=
 =

Total cost for this project =

CHAPTER-10

CONCLUSION
CHAPTER-10

CONCLUSION