MAJOR PROJECT REPORT

OF
COMPRESSED AIR ENGINE
Submitted in partial fulfillment of requirement of Bachelor of Technology
(B.TECH) M.E

B.TECH 7th SEMESTER

BATCH 2014-2018

Submitted To : Submitted By:

Er.Harkirat Singh Hitesh Dhiman 1632453
Jaskaran Singh 1632454
Pankaj Kumar 1632455
Rishab Jain 1632456
Ankush 1538216
Charanjeet 1538215

CT. INSTITUTE OF TECHNOLOGY & RESEARCH, JALANDHAR

Affiliated to
I.K GUJRAL PUNJAB TECHNICAL UNIVERSITY JALANDHAR
 MAJOR PROJECT REPORT
OF
COMPRESSED AIR ENGINE
Submitted in partial fulfillment of requirement of Bachelor of Technology
(B.TECH) M.E

B.TECH 7th SEMESTER

BATCH 2014-2018

Submitted To : Submitted By:

Er.Harkirat Singh Hitesh Dhiman 1632453
Jaskaran Singh 1632454
Pankaj Kumar 1632455
Rishab Jain 1632456
Ankush 1538216
Charanjeet 1538215

CT. INSTITUTE OF TECHNOLOGY & RESEARCH, JALANDHAR

Affiliated to
I.K GUJRAL PUNJAB TECHNICAL UNIVERSITY JALANDHAR
 ACKNOWLEDGMENT

We take the opportunity to express my cordial gratitude to Prof. Harkirat Singh,

Assistant Professor in the Department of Mechanical Engineering, CT Institute of
Technology & Research Jalandhar (Punjab) for the valuable guidance and inspiration
throughout the Project work. We feel thankful for his innovative ideas, which led to
successful completion of this work.
 ABSTRACT
The Air Driven Engine is an eco-friendly engine which operates with compressed
air.An Air Driven Engine uses the expansion of compressed air to drive the pistons of
an engine An Air Driven Engine is a pneumatic actuator that creates useful work by
expanding compressed air. There is no mixing of fuel with air as there is no
combustion.

An Air Driven Engine makes use of Compressed Air Technology for its operation
The Compressed Air Technology is quite simple. If we compress normal air into a
cylinder the air would hold some energy within it. This energy can be utilized for
useful purposes. When this compressed air expands, the energy is released to do
work. So this energy in compressed air can also be utilized to displace a piston.
 CONTENT

• INTRODUCTION
• LITERATURE REVIEW
• HISTORY
• ADVANTAGES
• RESEARCH WORK
• SAFETY FEATURES
• METHODLOGY
• COMPONENT
• ENGINE SPECIFICATION
• LAYOUT
• DESIGN & DRAWING
• COMPARISON
• EXPERIMENTAL METHOD
• ECONOMY ANALYSIS
• CYLINDER SPECIFICATION
• FUTURE SCOPE
• CONCULSON
 CHAPTER 1

INTRODUCTION
1.1 INTRODUCTION
At first glance the idea of running an engine on air seems to be too good to be true.
Actually, if we can make use of air as an aid for running an engine it is a fantastic
idea. As we all know, air is all around us, it never runs out, it is non-polluting and it is
free.

An Air Driven Engine makes use of Compressed Air Technology for its operation.
Compressed Air Technology is now widely preferred for research by different
industries for developing different drives for different purposes. The Compressed Air
Technology is quite simple. If we compress normal air into a cylinder the air would
hold some energy within it. This energy can be utilized for useful purposes. When this
compressed air expands, the energy is released to do work.

So this energy in compressed air can also be utilized to displace a piston. This is the
basic working principle of the Air Driven Engine. It uses the expansion of
compressed air to drive the pistons of the engine. So an Air Driven Engine is basically
a pneumatic actuator that creates useful work by expanding compressed air. This
work provided by the air is utilized to supply power to the crankshaft of the engine. In
the case of an Air Driven Engine, there is no combustion taking place within the
engine. So it is non-polluting and less dangerous. It requires lighter metal only since it
does not have to withstand elevated temperatures. As there is no combustion taking
place, there is no need for mixing fuel and air. Here compressed air is the fuel and it is
directly fed into the piston cylinder arrangement. It simply expands inside the cylinder
and does useful work on the piston. This work done on the piston provides sufficient
power to the crankshaft.
The laws of physics dictate that that uncontained gases will fill any given space .the
easiest way to see this in action is to inflate a balloon the elastic skin of the balloon on
holds the air .tightlyinside, but the moment you use a pin to create a hole in the
balloon's surface, the air expands outward with so much energy that the balloon
explodes. Compressing a gas into a small space is a way to store energy. When the
gas expands again, that energy is released to do work. That's the basic principle
behind what makes an air car move.Air car will have air compressor built into it.
After a brisk drive, we can take the car home, put it into the garage and plug in the
compressor. The compressor will use air from around the car to refill the compressed
air tank. Unfortunately, this is a rather slow method of refueling and will probably
take up few minutes for a complete refill. If the idea of an air car catches on, air
refueling stations will become available at ordinary gas stations, where the tank can
be refilled much more rapidly with air that's already been compressed.Filling your
tank at the pump will probably take about three minutes. This air car will almost
certainly use Compressed Air Motor (CAM) Pneumatic wrench. Air car propelled
with this engine will have tanks that will probably hold compressed air to about
11.03bar pressure. Its accelerator operates a valve on its tank that allows air to be
released into the hoses and then into the motor, where the pressure of the air's
expansion will push against the vanes and turn the rotor. This will produce enough
power for speeds of about 15-20 kilometers per hour.The laws of physics dictate that
uncontained Gases will fill any given space. The easiest way to see this in action is to
inflate a balloon. The elastic skin of the balloon holds the air It is hard to believe that
compressed air can be used to drive vehicles. However that is true and “air car” as it
popularly knows has caught the attention of research worldwide. It has zero emission
and is idealFor city driving condition. MDI (Meteor Development International) is
one company that holds the international patents for compressed air car. This review
study reveals aim is to run the four strokes bike with help of compressed air, it will
try to achieve a 50 km/h speed and range of refilling compressed air is after running
of 70-80 km.

Two technologies have been developed to meet different need

 Single energy compressed air engines.
Dual energy compressed air plus fuel engines

The single energy engines will be available in both Mini cats and City cats.
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 with use of
compressed air technology which having zero pollution level.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 2, 4 and 6 cylinders, When the air
tanks are empty the driver will be able to switch to fuel mode, by car’s on board
computer.

1.2 HOW COMPRESSED AIR CAN DRIVE A CAR

The laws of physics dictate that that uncontained gases will fill any given space .the
easiest way to see this in action is to inflate a balloon the elastic skin of the balloon on
holds the air .tightlyinside, but the moment you use a pin to create a hole in the
balloon's surface, the air expands outward with so much energy that the balloon
explodes. Compressing a gas into a small space is a way to store energy. When the
gas expands again, that energy is released to do work. That's the basic principle
behind what makes an air car move.
Fig.:1 Air car

Air car will have air compressor built into it. After a brisk drive, we can take the car
home, put it into the garage and plug in the compressor. The compressor will use air
from around the car to refill the compressed air tank. Unfortunately, this is a rather
slow method of refueling and will probably take up few minutes for a complete refill.
If the idea of an air car catches on, air refueling stations will become available at
ordinary gas stations, where the tank can be refilled much more rapidly with air that's
already been compressed.

Filling your tank at the pump will probably take about three minutes. This air car will
almost certainly use Compressed Air Motor (CAM) Pneumatic wrench. Air car
propelled with this engine will have tanks that will probably hold compressed air to
about 11.03bar pressure. Its accelerator operates a valve on its tank that allows air to
be released into the hoses and then into the motor, where the pressure of the air's
expansion will push against the vanes and turn the rotor. This will produce enough
power for speeds of about 15-20 kilometers per hour.
 CHAPTER 2

II. LITERATURE REVIEW

Air Powered Engine Prof. B.S Patel et al. tried to develop a compressed air engine by
modifying an 4-stroke, single cylinder SI engine by replacing the spark plug with a
pulsed pressure valve, and using compressed air as the working fluid. The working of
the engine is explained theoretically and the cost analysis is made which shows that
the compressed air engine is cheap when compared to the conventional SI engine.

2.1 Study of Compressed Air Storage System as Clean Potential

Energy for 21st Century

Dr. Bharat Raj Singh and Dr. Onkar Singh conducted an experiment in which they
used a vaned type novel air turbine as a prime mover for a motor bike. In this
experiment they tried to gain an output of 6.50 to 7.20 HP for the starting torque
requirements of 500 to 750 rpm at 4 to 6 bars air pressure to running speeds of 2000
to 3000 rpm using 2 to 3 bars air pressure. The test was conducted in HBTI Kanpur
and below diagrams shows the test rig setup and its layout:

Fig : 2 actual test rig.

 Fig : 3 test setup layout.

It consists of an air compressor which was used to produce and store 300 psi (21 bar
approx.) air and use it to impact the compressed air on the vanes of the novel air
turbine. The test was conducted at different inlet pressures and the efficiencies of the
turbine was found to vary from 72 to 97 %. The turbine had d/D ratio of 0.7 and the
results obtained were are follows:
93% to 99% with variation of 6%, at speed of rotation 500 rpm for injection
pressure 20 psi to 100 psi.
81.8% to 89.8% with variation of 8%, at the speed of rotation 1000 rpm for
injection pressure 20 psi to 100 psi.
70.8% to 84.3% with variation of 13.5%, at the speed of rotation 1500 rpm for
injection pressure 20 psi to 100 psi.
64.4% to 79.8% with variation of 15.4%, at the speed of rotation 2000 rpm for
injection pressure 20 psi to 100 psi.
59.5% to 76.5% with variation of 17%, at the speed of rotation 2500 rpm for
injection pressure 20 psi to 100 psi.
56.2% to 72.9% with variation of 16.7%, at the speed of rotation 3000 rpm for
injection

pressure 20 psi to 100 psi. A graph given below was drawn for comparing Actual
power with respect to theoretical power and the Speed of rotation in rpm:
 Fig: 4 A graph comparing Actual power with respecttotheoretical power and
the Speed of rotation inrpm

2.2 HISTORY

In fact, two centuries before that Dennis Paper in apparently came up with the idea of
using compressed air (Royal Society London, 1687).

In 1872 the Mikulski air engine was used for street transit, consisting of a single stage
engine. Numerous locomotives were manufactured and a number of regular lines
were opened up (the first in Nantes in 1879).

In 1892, Robert Hardier introduced a new method of heating that at the same time
served to increase the range of the engine which in turn helped to increase the
distance that could be traveled at a stretch. One of its new features was regenerative
braking. By using the engine as a compressor during deceleration, air and heat were
added to the tanks, increasing the range between fill-ups.

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 the compressed 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.

After twelve years of research and development, Guy Niger has developed an engine
that could become one of the biggest technological advances of this century. A French
engineer by profession, he has designed a low consumption and low pollution engine
for urban motoring that runs on compressed air technology. “air car” from

Motor Development International is a significant step for zero emission transport,

delivering a compressed air-driven vehicle that is safe, quiet, has a top speed of 110
km/h and a range of 200 km. Guy Niger is the head of Research and Development at
Meteor Development International (MDI)

2.3Advantages of compressed air powered vehicle:

In comparison to petrol or diesel powered vehicles “air powered vehicles” have

following advantages:

• Air, on its own, is non-flammable, abundant, economical, transportable, storable

and, most importantly, nonpolluting.
• Compressed air technology reduces the cost of vehicle production by about 20%,
because there is no need to build a cooling system, fuel tank, spark plugs or silencers.

• High torque for minimum volume.

• The mechanical design of the engine is simple and robust.
• Low manufacture and maintenance costs as well as easy maintenance.

• Lighter vehicles would mean less abuse on roads, thus, resulting in longer lasting
roads.
• The price of fueling air powered vehicles will be significantly cheaper than current
fuels.
• When the air is being compressed at reasonable speeds, it heats up. The heat given
off during compression could be reclaimed for space heating or water heating, or used
in a stirling engine.

• Transportation of the fuel would not be required due to drawing power off the
electrical grid. This presents significant cost benefits. Pollution created during fuel

transportation would be eliminated.

Compressed-air vehicles are comparable in many ways even to electric vehicles and
their potential advantages over electric vehicles include:

• Compressed-air vehicles are unconstrained by the degradation problems associated

with current battery systems.

• Much like electrical vehicles, air powered vehicles would ultimately be powered
through the electrical grid which makes it easier to focus on reducing pollution from
one source, as opposed to the millions of vehicles on the road.
• Compressed-air tanks can be disposed of or recycled with less pollution than
batteries.
• The tank may be able to be refilled more often and in less time than batteries can be
recharged, with refueling rates comparable to liquid fuels.

• The tanks used in a compressed air motor have a longer lifespan in comparison with
batteries, which, after a while suffer from a reduction in performance.

3.12 REVIEW OF PREVIOUS RESEARCH WORK

No more working on the single cylinder four strokes engine. But here few researches
are outlined as given below related to compressed air engine.

Air fuelled zero emission road transportation: A comparative study Haisheng

Chen et al. adopted two technologies typical compressed air and liquid air power
systems. Figure shows schematic diagram and working of cycle on temperature –
entropy diagram for the both systems. As per author’s knowledge and belief only few
works reported on this study.

Fig:19 Compressed air

engine
 Fig: 20 T–S diagram of engines Compressed
Following conditions are used in the analyses Ambient pressure: P1 = 1.013 bar.
Working pressure: P2 = 300 bar. Ambient temperature: T0 = 300 K. Volume of tank:
V = 300 lit.
The reasons to consider a fuel tank with 300 lit Volume and 300 bar working
pressure include:
(I) 300 l and 300 bar are technically feasible (ii) a High pressure and a large volume
are essential to give sufficient work output for an acceptable travel Distance and (iii)
compressed air vehicles with a 300 lit fuel tank within initial pressure of 300 bar have
been demonstrated practically. They have concluded in their paper is two types of air
fuelled engines for zero emission road transportation are compared in terms of their
shaft work, coolth, efficiency and energy density. It was found that the shaft work
output and the coolth of both the fuels increase with increasing working pressure or
temperature. Given the working pressure and temperature, liquid air powered engines
have a slightly lower specific work outputs than compressed air powered engines. At
P = 300 bar and T = 300 K, the practical net work outputs of the compressed air
engine for isothermal ties of γ= 0.75 and 0.90 are respectively 222.8 kJ/kg and

284.2 kJ/kg, whereas the corresponding values for the liquid air engines are 184.1
kJ/kg and 245.6 kJ/kg. The volumetric energy density of liquid air fuel, however, is
about 2.45 times that of compressed air fuel, and liquid air engines produce much
more coolth than compressed air engines. On the other hand, the efficiency of
compressed air powered engine is higher than that of liquid air powered engines,
mainly because of its high energy consumption of liquefaction plants. Their analyses
also suggested that an effective use of coolth is a key to improve the overall efficiency
of liquid air powered engines. A novel compression strategy for air hybrid engines
Amir Fazelietal.have proposed utilizing of two storage tanks which increases the
efficiency of regenerative braking of air hybrid vehicles significantly by increasing
the stored air mass and, consequently, the storing pressure in the tank. Air hybrid
engines have different operational modes. Illustrates the energy flow at different
operational mode.

Fig: 21 Energy flow at different operational mode

The theoretical and experimental results showed the advantage of the proposed
strategy over the conventional single-storage system. The proposed compression
algorithm can be utilized in an air hybrid vehicle to increase the efficiency of energy
recovery by the compression braking system. Compared to the double-stage
regenerative braking, the double-tank system doubles the air flow rate because only
one cylinder is needed to implement the proposed concept and thus, all the cylinders
can be connected directly to the main tank. The proposed compression algorithm can
be applied not only in air hybrid vehicle compression braking system, but also in any
other applications, where higher pressure with higher air mass flow rate is demanded
such as typical reciprocating compressors.

3.13 SAFETY FEATURES OF THE AIR CAR

1. That means that the tanks are prepared and certified to carry explosive product
methane Gas. In the case of an accident with air tank Breakage, there would be
no explosion or shattering for the tanks that are not metallic but made of glass
fiber.
 2. The tanks would crack longitudinally, and the air would escape, causing a
strong buzzing sound with no dangerous factor.

3. It is clear that if this technology has been tested and prepared to carry an
inflammable and explosive Gas, it can also be used to carry air.

CHAPTER 3

METHODOLOGY

At first glance the idea of running an engine on air seems to be too good to be true.
Actually, if we can make use of air as an aid for running an engine it is a fantastic
idea. As we all know, air is all around us, it never runs out, it is non-polluting and it is
free.

An Air Driven Engine makes use of Compressed Air Technology for its operation.
Compressed Air Technology is now widely preferred for research by different
industries for developing different drives for different purposes. The Compressed Air
Technology is quite simple. If we compress normal air into a cylinder the air would
hold some energy within it. This energy can be utilized for useful purposes. When this
compressed air expands, the energy is released to do work.

So this energy in compressed air can also be utilized to displace a piston. This is the
basic working principle of the Air Driven Engine. It uses the expansion of
compressed air to drive the pistons of the engine. So an Air Driven Engine is basically
a pneumatic actuator that creates useful work by expanding compressed air. This
work provided by the air is utilized to supply power to the crankshaft of the engine.
In the case of an Air Driven Engine, there is no combustion taking place within the
engine. So it is non-polluting and less dangerous. It requires lighter metal only since it
does not have to withstand elevated temperatures.

As there is no combustion taking place, there is no need for mixing fuel and air. Here
compressed air is the fuel and it is directly fed into the piston cylinder arrangement. It
simply expands inside the cylinder and does useful work on the piston. This work
done on the piston provides sufficient power to the crankshaft.

3.2 Keywords:

Air, Compressed, Engine, Energy, Propulsion, Pneumatic

3.3 Components

CYLINDER

PISTON

COMBUSTION CHAMBER

CONNECTING ROD

CRANKSHAFT

CAMSHAFT

CAM
 PISTON RINGS

GUDGEON PIN

INLET

EXHAUST MANIFOLD

INLET AND EXHAUST VALVE

FLYWHEEL

3.4 Engine Specifications

Type of fuel used : Air

Cooling system : Air cooled
Number of cylinder : Single
Number of stroke : Two Stroke
Arrangement : Vertical
Cubic capacity : 100 cc
3.5 Layout of the Project

Fig.: 13 Layout of the

Project
3.6 Compressed Air Engine Principle

A compressed-air vehicle is powered by an air engine, using compressed air, which is

stored in a tank. Instead of mixing fuel with air and burning it in the engine to drive
pistons with hot expanding gases, compressed air vehicles (CAV) use the expansion
of compressed air to drive their pistons. One manufacturer claims to have designed an
engine that is 90 percent efficient. Compressed air propulsion may also be
incorporated in hybrid systems, e.g., battery electric propulsion and fuel tanks to
recharge the batteries. This kind of system is called hybrid-pneumatic electric
propulsion. Additionally, regenerative braking can also be used in conjunction with
this system.

A. Engine

A Compressed -air engine is a pneumatic actuator that creates useful work by

expanding compressed air. They have existed in
many forms over the past two centuries, ranging in size from hand held turbines up to
several hundred horsepower. Some types rely on pistons and cylinders, others use
turbines.
Many compressed air engines improve their performance by heating the incoming air,
or the engine itself. Some took this a stage further and burned fuel in the cylinder or
turbine, forming a type of internal combustion engine. One can buy the vehicle with
the engine or buy an engine to be installed in the vehicle. Typical air engines use one
or more expander pistons. In some applications it is advantageous to heat the air, or
the engine, to increase the range or power.
B. Tank

The tanks must be designed to safety standards appropriate for a pressure vessel, such
as ISO 11439.

The storage tank may be made of:

1. Steel,

2. Aluminum,

3. Carbon fiber,

4. Kevlar,

5. Other materials or combinations of the above.

The fiber materials are considerably lighter than metals but generally more expensive.
Metal tanks can withstand a large number of pressure cycles, but must be checked for
corrosion periodically. One company stores air in tanks at 4,500 pounds per square
inch (about 30 MPa) and hold nearly 3,200 cubic feet (around 90 cubic metres) of air.

The tanks may be refilled at a service station equipped with heat exchangers, or in a
few hours at home or in parking lots, plugging the car into the electrical grid via an
on-board compressor.

C. Compressed Air

Compressed air has a low energy density. In 300 bar containers, about 0.1 MJ/L and
0.1 MJ/kg is achievable, comparable to the values of electrochemical lead-acid
batteries. While batteries can somewhat maintain their voltage throughout their
discharge and chemical fuel tanks provide the same power densities from the first to
the last litre, the pressure of compressed air tanks falls as air is drawn off. A
consumer-automobile of conventional size and shape typically consumes 0.3-0.5 kWh
(1.1-1.8 MJ) at the drive shaft per mile of use, though unconventional sizes may
perform with significantly less.

D. Emission Output

Like other non-combustion energy storage technologies, an air vehicle displaces the
emission source from the vehicle’s tail pipe to the central electrical generating plant.
Where emissions-free sources are available, net production of pollutants can be
reduced. Emission control measures at a central generating plant may be more
effective and less costly than treating the emissions of widely-dispersed vehicles.

Since the compressed air is filtered to protect the compressor machinery, the air
discharged has less suspended dust in it, though there may be carry-over of lubricants
used in the engine.

3.7 Working Principle

Today, internal combustion engines in cars, trucks, motorcycles, aircraft, construction

machinery and many others, most commonly use a four-stroke cycle. The four strokes
refer to intake, compression, combustion (power), and exhaust strokes that occur
during two crankshaft rotations per working cycle of the gasoline.

engine and diesel engine.

The cycle begins at Top Dead Center (TDC), when the piston is farthest away from
the axis of the crankshaft. A stroke refers to the full travel of the piston from Top
Dead Center (TDC) to Bottom Dead Center (BDC).

A. INTAKE stroke

On the intake or induction stroke of the piston , the piston descends from the top of
the cylinder to the bottom of the cylinder, reducing the pressure inside the cylinder. A
mixture of fuel and air is forced by atmospheric (or greater) pressure into the cylinder
through the intake port. The intake valve(s) then close.

B. COMPRESSION stroke

With both intake and exhaust valves closed, the piston returns to the top of the
cylinder compressing the fuel-air mixture. This is known as the compression stroke.

C. POWER stroke

While the piston is close to Top Dead Center, the compressed air–fuel mixture is
ignited, usually by a spark plug (for a gasoline or Otto cycle engine) or by the heat
and pressure of compression (for a diesel cycle or compression ignition engine). The
resulting massive pressure from the combustion of the compressed fuel-air mixture
drives the piston back down toward bottom dead center with tremendous force. This
is known as the power stroke, which is the main source of the engine’s torque and
power.
D. EXHAUST stroke

During the exhaust stroke, the piston once again returns to top dead center while the
exhaust valve is open. This action evacuates the products of combustion from the
cylinder by pushing the spent fuel-air mixture through the exhaust valve(s).
In our project we have to modified these four strokes into totally two stoke with the
help of inner CAM alteration. In air engine we can design a new CAM which is
operate only Inlet stroke and exhaust stroke. Actually in four stroke engine the inlet
and exhaust valve opens only one time to complete the total full cycle. In that time the
piston moving from top dead center to bottom dead center for two times. A stroke
refers to the full travel of the piston from Top Dead Center (TDC) to Bottom Dead
Center (BDC).In our air engine project, we have to open inlet and exhaust valve in
each and every stroke of the engine so that it will convert the four stroke engine to
two stroke engine by modifying the CAM shaft of the engine.

3.8 Design and Drawings

A. Design of Ball Bearing

Bearing No. 6202

Outer Diameter of Bearing (D) = 35 mm
Thickness of Bearing (B) = 12 mm
Inner Diameter of the Bearing (d) = 15 mm
r = Corner radii on shaft and housing
r₁ = 1 (From design data book)
Maximum Speed = 14,000 rpm (From design data book)
Mean Diameter (dm) = (D + d) / 2
= (35 + 15) / 2
dm = 25 mm

Comparison between SI engine and compressed air engine

Compressed air technology attracts the researchers and several industries world
widely. Compressed air engine operates with the compressed air and is very simple in
construction and operation .Here, compressed air from the air cylinder pushes the
piston giving the power stroke. In the next stroke piston escape the expanded air from
the cylinder. The cycle is completed in two strokes. Therefore, uniform turning effort
is obtained unlike four stroke engine

Fuel tank and spark plug is eliminated from the conventional four stroke engine.

In the case of a compressed air Engine, there is no combustion taking place within the
engine. So it is less dangerous and non-polluting. It requires lighter metal only since it
does not have to withstand elevated temperatures. As there is no combustion taking
place and Carburetor is eliminated because carburetor is used for mixing of fuel and
air purpose. There is no need for mixing fuel and air, here compressed air is the fuel
and it is directly fed into the piston cylinder arrangement. It simply expands inside the
cylinder and does useful work on the piston. This work done on the piston provides
sufficient power to the crankshaft. The above experiment and modification is done on
the motorcycle engine of Hero Honda (Model- Hero Honda Passion).

WORKING OF FOUR STROKE SI ENGINEA four-stroke engine is an IC engine

in which the Piston completes four strokes. A stroke refers to the full travel of the
piston along the cylinder, in either direction. The four strokes are as follows-
INTAKE: -

This stroke of the piston begins at top dead center. The piston descends from the top
of the cylinder to the bottom of the cylinder, increasing the volume of the cylinder. A
mixture of fuel and air is forced by atmospheric (or greater) pressure into the cylinder
through the intake port.

COMPRESSION: -
With both intake and exhaust valves closed, the piston returns to the top of the
cylinder compressing the air or fuel-air mixture into the cylinder head.

EXPANSION: -

This is the start of the second revolution of the cycle. While the piston is close to Top
Dead Center, the compressed air–fuel mixture in a gasoline engine is ignited, by a
spark Plug in gasoline engines, or which ignites due to the heat generated by
compression in a diesel engine. The resulting pressure from the combustion of the
compressed fuel-air mixture forces the piston back down toward bottom dead center.

EXHAUST: -

During the exhaust stroke, the piston once again returns to top dead center while the
exhaust valve is open. This action expels the spent fuel-air mixture through the
exhaust valve(s).
WORKING OF MODIFIED COMPRESSED AIR ENGINE
A compressed air engine is an engine in which the piston completes two separates
strokes. A stroke refers to the full travel of the piston top dead center to bottom dead
center or bottom dead center to top dead center along the cylinder, in either direction.
There are two commonly used termed as follows:-

INTAKE; -
In this stroke inlet valve opens and exhaust valve closed. Compressed air enters in
the cylinder during this stroke at pressure of 87.02264 Psi or 6 Bar to 94.27452 Psi
6.5 Bar. This stroke of the piston starts at top of the cylinder to the bottom of the
cylinder by compressed air, increasing the volume of the cylinder.

EXHAUST: -
In this stroke inlet or intake valve closed and exhaust valve opens. The piston once
again returns to top dead center and compressed air are pushed out to the cylinder into
the atmosphere to the movement of piston through exhaust valve.
The working of modified compressed air engine is also shown in fig:-
EXPERIMENTAL METHOD

A) Experimental Setup:-
B) For carrying out the research, Petrol engine of HERO HONDA PASSON PRO
of 100 cc was used . As petrol is not being used in this experiment, so there
was no need of the carburetor and thus the carburetor was removed. There is
no combustion taking place inside the engine, so there is no need of a spark
plug, so the spark plug is also removed.
In the inlet valve a hose (pipe) is attached and a regulator was also attached on the top
of the cylinder. So that the starting pressure 87.02264 Psi or 6 bars to 94.27452 Psi or
6.5 bar could be made. When the regulator was opened air entered into the cylinder
through the pipe. When the air entered at a pressure of 6 bar the piston moved from
Top dead center to Bottom dead center (TDC to BDC).and piston reaches at bottom
dead center. After that, the piston started to move from Bottom dead center to Top
dead center due to the weight of the flywheel. As piston started

To move upwards the engine stopped working. This was because the exhaust valve
did not open and the compressed air did not moved out. So, engine stopped there. To
overcome this a cam was designed. The engine used in the experiment had cam of
two cam lobes. And the fig. (c) is shown the cam of the engine

Camshaft of an engine with two lobes

Camshaft of an engine with four lobes

To overcome this, in addition to two cam lobes, a new cam lobe was attached.
Further, to make the exhaust valve open again one more cam lobe was attached.
When the four cam lobes were attached, the engine started to work due to this, the
petrol engine started to work as a compressed air engine in which there is no need of
petrol and combustion. The specification of an engine is given below:-

Engine Specification:-

Economy Analysis:-

A metallic cylinder of 60 Inches or 152.4 cm with adiameter 12 Inches or

30.48 cm was taken. The inside pressure was taken to be 140 Psi or 9.65266
 Bar in half and 300 Psi or 21.6975 Bar (Maximum). The cost to fill the
cylinder was Rs. 6. The engine was started by using this cylinder. The engine
runs for 8-10 km (depending upon the conditions).

This experiment was repeated several times to check and the resulting
average was between 7-9.5, 8-10 & 8.5-10. On an average it can cover 1 km in
0627 paisa. The air cylinder specification is given below:-

Air Cylinder Specification

Type Metallic/ Steel/

Regulator and
Length 60 Inches or 152.4
Cm
Diameter 1 feet or 30.48 cm

Inside Pressure 140 Psi or 9.65266

Bar in half
300 Psi or 21.6975
Regulating
Pressure 101.526 Psi or 7 Bar

Engine Starting
pressure 87.02264 Psi or 6 Bar
to 94.27452 Psi 6.5

Volume 300 Pond

 Type Air-cooled, 4-stroke
single cylinder OHC

Displacement 97.2 cc

Max. Power 5.74 kW (7.8 Ps) at 7500

Rpm
Max. Torque 0.82 Kgf-m (8.04 N.m) at
4500 rpm
Bore x Stroke 50.0 x 49.5 mm

Compression Ratio 9.0: 1

Starting Kick start

Advantages

• Compressed air to store the energy instead of batteries.

• Pollution created during fuel transportation would be eliminated.

• Reducing pollution from one source, as opposed to the millions of vehicles on the
road.

• There is no need to build a cooling system, fuel tank, Ignition Systems or

silencers.
• The price of fueling air powered vehicles will be significantlycheaper than current
fuels.

• Disadvantages

• 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 a long time.
• Tanks get very hot when filled rapidly. It very dangerous ifcaution is not
maintained.
Only limited storage capacity of the tanks. So we cannot opt for a long drive

3.9 Applications

•Compressed air engines were used in trams and shunters, and eventually found a
successful niche in mining locomotives
•Transport category airplanes, such as commercial airliners, use compressed air
starters to start the main engines. The air is supplied by the load compressor of the
aircraft's auxiliary power unit, or by ground equipment.
•There is currently some interest in developing air cars. Several engines have been
proposed for these
•Impact wrenches, drills, firearms, die grinders, dental drills and other pneumatic
tools use a variety of air engines or motors. These include vane type pumps, turbines
and pistons.
Most successful early forms of self-propelled torpedoes used high pressure
compressed air, although this was superseded by internal or external combustion
engines, steam engines, or electric motors
 • Mopeds
Jem Stansfield, an English inventor has been able to convert a regular scooter to a
compressed air moped. This has been done by equipping the scooter with a
compressed air engine and air tank.
• Buses
MDI makes MultiCATs vehicle that can be used as buses or trucks. RATP
has also already expressed an interest in the compressed-air pollution-free
bus.
• Locomotives
Compressed air locomotives have been historically used as mining
locomotives and in various areas.
• Trams
Various compressed-air-powered trams were trialed, starting in 1876 and
has been successfully implemented in some cases.
e) Watercraft and aircraft
Currently, no water or air vehicles exist that make use of the air engine.
Historically compressed air engines propelled certain torpedoes

Connecting rod:

Connecting rod is a part of the engine which is used to transmit the push and
pull from the piston pin to the crank pin. In many cases, its secondary
function is to convey the lubricating oil from the bottom end to the top end
i.e. from the crank pin to the piston pin and then for the splash of jet cooling
of piston crown. The usual form of connecting rod used in engines has an eye
at the small end for the piston pin bearing, a long shank, and a big end
opening which is usually split to take the crankpin bearing shells.
The connecting rods of internal combustion engine are mostly manufactured
by drop forging. The connecting rod should have adequate strength and
stiffness with minimum weight. The materials for connecting rod range from
mild or medium carbon steel to alloy steels.
In industrial engines, carbon steel with ultimate tensile strength ranging from
550 to 670 MPa is used. In transport engines, alloy steel having a strength of
about 780 to 940 MPa is used e.g., manganese steel. In aero engines, nickel
chrome steel having ultimate tensile strength of about 940 to 1350 MPa is
most commonly used.
For connecting rod of low speed horizontal engines, the material may be
sometimes steel castings. For high speed engines, connecting rod may also be
made up of duralumin and aluminium alloys.
The usual shape of connecting rod is:
Rectangular
Circular
Tubular
I section
H section
In low speed engines, the section is usually circular with flattened sides, or
rectangular, the larger dimension being in the plane of rotation. In high speed
engines, lightness of connecting rod is a major factor. Therefore tubular, Isection
or H-section rods are used.
The length of the connecting rod depends upon the ratio of connecting rod
length and stroke i.e. l/r ratio; on l/r ratio depends the angularity of the
connecting rod with respect to the cylinder centre line. The shorter the length
of the connecting rod l in respect to the crank radius r, the smaller the ratio
l/r, and greater the angularity. This angularity also produces a side thrust of
the piston against the liner. The side thrust and the resulting wear of the liner
decreases with a decrease in the angularity. However, an increase of l/r ratio
increases the overall height of the engine. Due to these factors, the common
values of l/r ratio are 4 to 5.
The stresses in the connecting rod are set up by a combination of forces. The
various forces acting on the connecting rod are:
1. The combined effect of gas pressure on the piston and the inertia of the
reciprocating parts.
2. Friction of the piston rings and of the piston.
3. Inertia of the connecting rod.
4. The friction of the two end bearings i.e. of the piston pin bearing and the crank pin
bearing.
2.1.3. Bearing:
The concept behind a bearing is very simple: Things roll better than they slide. The
wheels on your car are like big bearings. If you had something like skis instead of
wheels, your car would be a lot more difficult to push down the road. That is because
when things slide, the friction between them causes a force that tends to slow them
down. But if the two surfaces can roll over each other, the friction is greatly reduced.
Bearings reduce friction by providing smooth metal balls or rollers, and a smooth
inner and outer metal surface for the balls to roll against. These balls or rollers "bear"
the load, allowing the device to spin smoothly.

Working of a Bearing:
As one of the bearing races rotates it causes the balls to rotate as well. Because the
balls are rolling they have a much lower coefficient of friction than if two flat surfaces
were rotating on each other.
Ball bearings tend to have lower load capacity for their size than other kinds of
rolling-element bearings due to the smaller contact area between the balls and races.
However, they can tolerate some misalignment of the inner and outer races.
Compared to other rolling-element bearings, the ball bearing is the least expensive,
primarily because of the low cost of producing the balls used in the bearing.

Types of Bearings:
There are many types of bearings, each used for different purposes. These include ball
bearings, roller bearings, ball thrust bearings, roller thrust bearings and tapered roller
thrust bearings.

Cut away view of a ball bearing Cut away view of a roller bearing
Ball thrust bearing Roller thrust bearing

Cutaway view of (left) a spherical roller thrust bearing and (right) a radial
tapered roller bearing

Bearing Loads:
Bearings typically have to deal with two kinds of loading, radial and thrust.
Depending on where the bearing is being used, it may see all radial loading, all
thrust loading or a combination of both.

The bearings that support the shafts of motors and pulleys are subject to a radial load.

Bearing Used:
Ball bearings

A ball bearing is a type of rolling-element bearing which uses balls to maintain

the separation between the moving parts of the bearing. The purpose of a ball
bearing is to reduce rotational friction and support radial and axial loads. It
achieves this by using at least two races to contain the balls and transmit the
loads through the balls. Usually one of the races is held fixed.

FUTURE SCOPE
This work of our project will explores performance of CAE (Compressed Air Engine)
on the 4-S single cylinder 100cc engine. As per our knowledge and percentage of
success on work of CAE can be used in commercial bike, bicycle with a few
modifications. That will help to minimize the pollutions level and dependency upon
conventional source of energy and also be economical and become a new alternative
for automotive purpose.

Following future scopes are possible of this project work.

• The same study can be investigated with new light weight design of piston
because of no combustion mean no thermal expect is considering in the design
of piston, cylinder and other parts.

• The same study is carried out with other gases having more compressibility and
more energy density.

• Engine is completely design for the compressed air which omits the
convectional parts like catalytic convertor, spark plug, engine fins, carburetor
etc.

• Development is more consent on the storage devices.

 • In future same development is carried out with dual energy.

CONCLUSIONS

Nowadays continue need of energy is increases, but basically conventional source of

energy is limited due to that rate on price of petroleum is also continues hiked day by
day. To satisfy there need alternate fuel or energy is required. But while considering
alternate fuel some of factors are to be considered like availability, economy, and
environment friendly etc., based on that CAT (Compressed Air Technology) is best
technology which tend engine to zero pollutions. 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.

FINAL PROJECT