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iirdem CRASH IMPACT ATTENUATOR (CIA) FOR AUTOMOBILES WITH THE ADVOCATION OF MECHATRONIC SYSTEMS
1.
CRASH IMPACT ATTENUATOR
(CIA) FOR AUTOMOBILES WITH THE ADVOCATION OF MECHATRONIC SYSTEMS [1]M.ASHWIN, [2] BHUVANESWARAN P, [3] VARUN.C [1]SRM EASWARI ENGINEERING COLLEGE, [2] PANIMALAR INSTITUTE OF TECHNOLOGY, [3] PANIMALAR ENGINEERING COLLEGE. [1]ashwinmurali@outlook.com, [2] iambhuvan@outlook.com, [3]varuncharavanan14@gmail.com. ABSTRACT For the past two decades there has been an upsurge in the road accidents due to car crashes. Nearly 1.3 million people die in car crashes each year, on average 3,287 deaths a day. Even though there is so much of developments in the field of automobile there is no sophisticated system for securing the vehicle as well as its passengers during the crash. There are some existing electronic systems for preventing the crashes but they are not completely reliable so it is better to absorb the crash impact than trying to prevent it. So in this project we are introducing a crash absorption system which completely absorbs the crash impact force when two cars collide. Rubber attached bracket and torsion bar constitute the crash absorption system. This system is controlled by programmed microcontroller which makes this system function able only at the time of accident. Ultrasound sensors and infrared sensors assist in increasing the efficiency of the system. Hence we propose that this system can reduce the effects of crash and has the potential to save human lives. Keywords: ultrasound sensor, bracket, microcontroller and crash absorption. INTRODUCTION Road accidents have been increasing at an enormous rate since the development of vehicles. In the past three decades car accidents have been responsible most of the accidents. Car accidents are very much destructive, they cause damage to car body resulting in huge loss at the same time they can also claim human lives depending upon the intensity of the accidents. Accidents are the prime concern for most of the automobile companies. Many systems have been developed which mainly focuses on accident prevention. These systems are automatically controlled through electronic systems. In reality these systems are not completely effective in averting accidents. Accident prevention systems can just warn the driver or apply brakes automatically before a crash which cannot stop a high speed approaching vehicle. So it is better to absorb the impact of the crash then trying to prevent it. So this paper targets the concept of collision impact absorption aided by an electronic system incorporating cloud computation. The main idea is to develop a lightweight, extremely effective energy absorption system for improving the energy management effectiveness of the primary crush zone of a vehicle. While protecting a vehicle's occupants from injury in a crash is a challenge for every vehicle manufacturer, in the case of a small, lightweight car , it is a particular challenge, due in part to the limited ability of small cars to absorb collision energy, and the relative short crush distance which is a major factor in providing a ride-down or deceleration distance for the vehicle occupants. In a conventio33nal steel-bodied vehicle, the body panels are shaped and reinforced to form crush or crumple zones that are designed to absorb collision energy while protecting the passenger compartment or so-called occupant interior cage. Smaller, lighter weight cars offer particular challenges to engineers to provide adequate crash energy absorption. Efforts to improve passenger compartment protection typically add weight to the vehicle and thus adversely affect fuel economy. LITRATURE REVIEW Kenji Fujita invention objective was to provide an automatic drive system to a car which can recognize the surrounding and react in accordance to that of a path ahead of the car, such as a camera, and a transmitter. On ISBN-13: 978-1539045540 www.iirdem.org Proceedings of ICEEM-2016-Chennai ©IIRDEM 201612
2.
the basis of
the driving situation of the car, which is identified on the basis of conditions recognized by the control system, a control scheduling means selects at least one among multiple of control programs. Car control is provide to braking system and a steering system, automatically controlled with the most effective control program to drive the car so as to avoid a possible crash against an obstruction in the way ahead of the car Jan Willem Vermeulen et al., invented a Part that can be fixed to the front part of automobile, consists of a supporting construction which is assembled from various parts manufactured from different metal plate material and provided with attachments for fixing the guard to the vehicle, a plastic cover element is separately covering the sides of each profile part facing away from automobile, and the connecting members connect the cover element to support the construction, and between the profile parts of the supporting construction and the cover element free space is present and the cover element is deformable plastic Bruce Leigh Kiehne designed a vehicle with an accident prevention system. The vehicle has conventional foot brake for halting the vehicle. The system includes a sensor system for sensing an object behind the vehicle that generates an object identification signal when it senses an object within range behind the vehicle. The sensor arrangement is inclusive of passive IR sensors or reflected pulse sensors such as sonar or radar sensors on the end. A controller creates an accident prevention response signal on receiving the data that is object recognition signal from the sensor system. A brake applying mechanism is parallely coupled to the brake to stop the vehicle when the controller generates a response signal. Conveniently the system comes with an alarm signal. A method to prevent accident whenever a vehicle is reversing the problem of collision with a person is also dealt with. Hyoung Pyo Hong patented an accident prevention apparatus for a car is disclosed, which is provided at a front of a car to protect a hit pedestrian by deploying a safety cover upon collision with the pedestrian. The accident prevention apparatus comprises a sensing unit which detects a collision impact, and a driving unit which deploys the safety cover according to the operation of the sensing unit. The sensing unit comprises a receiver and a connection bar connecting the receiver to the driving unit, while the driving unit comprises a bursting part operated by the connection bar, and a deploying part deploying the safety cover according to the operation of the bursting part. Since the accident prevention apparatus is built in a main body of a driving unit when not in use and promptly deploys a safety cover upon a collision accident in accordance with the car speed and efficiently captures the hit pedestrian, safety of the collision victim is greatly improved. Also, chain collision by following cars and other sequential accidents can be prevented. ROAD ACCIDENTS STATISTICS: Nearly 1.3 million people die in road crashes each year, on average 3,287 deaths a day. An additional 20-50 million are injured or disabled. More than half of all road traffic deaths occur among young adults ages 15-44. Road traffic crashes rank as the 9th leading cause of death and account for 2.2% of all deaths globally. Road crashes are the leading cause of death among young people ages 15-29, and the second leading cause of death worldwide among young people ages 5-14. Each year nearly 400,000 people under 25 die on the world's roads, on average over 1,000 a day. Over 90% of all road fatalities occur in low and middle-income countries, which have less than half of the world's vehicles. Road crashes cost USD $518 billion globally, costing individual countries from 1-2% of their annual GDP. Road crashes cost low and middle-income countries USD $65 billion annually, exceeding the total amount received in developmental assistance. Unless action is taken, road traffic injuries are predicted to become the fifth leading cause of death by 2030. ISBN-13: 978-1539045540 www.iirdem.org Proceedings of ICEEM-2016-Chennai ©IIRDEM 201613
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COMPONENTS: ACCIDENT PREDICTION SYSTEM Fig1:
ULTRASOUND SENSOSR Fig2: DB9 CABLE The crash prediction system consists of ultrasound sensors for measuring the distance between the driving vehicle and the approaching vehicle. The ultrasound sensors are placed on all the 4 sides of a car for getting a complete 360 degree view of the surroundings. An OBD is utilized for providing speed data. CAN BUS and DB9 cables are used for data transmission from OBD. A microcontroller is placed near the OBD which collects all the data, processes the information and decides whether or not to activate the system. CRASH ABSORPTION SYSTEM Fig3 TORSION BAR The crash absorption system consists of pneumatic circuit consisting of a compressor, reservoir, FRL unit, 5/2 valve and a cylinder placed adjacent to the car chassis. The compressor compresses atmospheric air and then sends it to the reservoir. From the reservoir air enters the cylinder through a solenoid controlled 5/2 valve. The functioning of the solenoid valve and its actuation time is pre-programmed in the microcontroller. FRL unit regulates the process and assist in proper functioning of the pneumatic system. The cylinder is attached to the chassis by an U-clamp. To the U-clamp the cylinder is welded horizontally. The piston pushes and pulls back a shock energy absorber. The shock energy absorber is the main crash absorbing component of the system. The shock energy absorber is made up of RZ5 magnesium alloy as it is light in weight and has good strength for withstanding impact loads. The shock energy absorber contains torsion bar, which acts as the shock absorbing component. In addition to the torsion bar a thick layer of rubber is placed between the shock energy absorber for damping the vibrations. Another layer of rubber is placed on the curved portion of the shock energy absorber where the first impact happens. The shock energy absorber pivots on a shaft which is attached to the car chassis. This RZ5 magnesium alloy shaft also helps in holding the torsion bar firmly. Its composition is zinc rare earth metals and zirconium. DESIGN OF TORSION BAR The Torsion bar was designed in catia V5 and analysed in ANSYS Workbench V 15.0. Torsion bars of various diameters were designed and analysed by trial and error method. Since there are two torsion bars used in the system the load gets divided into two. Considering a maximum impact from a car approaching at 60km/hr 900KN-m moment was applied on the torsion bar. The torsion bar was found to be safe for a diameter of 60mm and the factor of safety was obtained as 1. Material that was used for torsion bar is AISI 4140. Mechanical properties of AISI 4140 for a section of 60mm are Yield Strength= 770Mpa Tensile Strength= 930Mpa ISBN-13: 978-1539045540 www.iirdem.org Proceedings of ICEEM-2016-Chennai ©IIRDEM 201614
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Elongation=17% Impact Izod= 90J Hardness=
275 HB Fig 4 Design of torsion bar with the fixed support Fig 5 Moment is applied on the torsion bar Fig 6 Total deformation Fig 7 Equivalent Stress Fig 8 Strain Energy Fig 9 Safety Factor SPECIFICATIAONS Ultra sound sensor-Hc-sr04 Working voltage DC 5 v Working current 15mA Working frequency: 40 Hz Max range 4 m Min range 2 m Measuring angle 15 degrees Trigger input signal: 10 micro seconds TTL pulse Echo output signal input TTL lever signal and range in position Dimensions 45*20*15 Hardware used - Intel Edison Intel atom dual core Processor 500 mhz Ram 1Gb DDR3 Rom eMMC 4Gb flash Bluetooth 4.0 Wifi On-board diagnostics (OBD) is an device used for self diagnostic and problem identification in an automobile. WORKING: ACCIDENT PREDICTION SYSTEM On board diagnostic (OBD) is used to transmit the speed of the vehicles to microcontroller. OBD is present in almost every car to get access to the status of vehicle subsystems. From the OBD various parameters can be obtained , upto 16 data like speed, temperature etc. from various sensors. In this system it works on cloud principle. Every vehicles speed is sent to the cloud from the OBD where it is shared to the other vehicles OBD. The OBD gets the speed of every approaching vehicle and transmits it to the microcontroller along with the own vehicle speed. A CAN BUS is utilized to connect the microcontroller and the OBD for effective data ISBN-13: 978-1539045540 www.iirdem.org Proceedings of ICEEM-2016-Chennai ©IIRDEM 201615
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transmission between them.
The data from CAN BUS is transferred through a DB9 cable to the microcontroller. Simultaneously the ultrasound sensor calculates the distance between the approaching vehicle and the driving vehicle to the microcontroller. Once the microcontroller gets all three data, it substitutes’ it in the condition programmed. When the condition gets satisfied the crash absorption system gets activated. The microcontroller supplies current to the pump from the battery. BLOCK DIAGRAM Fig 10: Block Diagram CRASH ABSORPTION SYSTEM The reservoir is filled by the compressor and it is constantly checked for pressure loss by the microcontroller. When the sensors sense crash, the microcontroller activates the crash absorption system The air from the reservoir enters the cylinder and inturn it pushes the shock energy absorber. The shock energy absorber rotates on a pivoting shaft and comes protruding out of the car for a distance of 18cm. So that the first impact of the colliding car is on the crash bar. The first impact area is completely made up of thick rubber, which absorbs most of the impact load. The shock energy absorber contains high performance torsion bar for absorbing the crash energy. So when a car hits the shock energy absorber bar, it compresses due to the rotation of torsion bar. Finally the rotation of torsion bar is damped by another set of thick rubber which completely eradicates the crash energy from reaching the car body. The shock energy absorber looks as a car skirt until it operates and comes into position once a crash is predicted. In this way the car can be secured during a crash and damage to body as well as the passengers can be prevented with less damage on the shock energy absorber. DESIGN AND ANALYSIS The design was done using catia V5. The assembly view consists of the crash energy absorber and the pneumatic circuit. Fig11: ISOMETRIC VIEW 1 Fig12: ISOMETRIC VIEW 2 Fig13: ISOMETRIC VIEW 3 ISBN-13: 978-1539045540 www.iirdem.org Proceedings of ICEEM-2016-Chennai ©IIRDEM 201616
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Fig14: TOTAL DEFORMATION
1 Fig15: TOTAL DEFORMATION 2 CONCLUSION Thus we have designed a crash safety system which is especially for four wheeled vehicles. This safety system will be very effective in any road conditions. It has the potential to minimise the effect of crashes and it can prevent car body from getting damaged. Apart from that it can protect the passengers even during high speed head on collisions. It can be installed in any cars. So we hope it has the potential to save human lives. REFERENCE: [1] https://en.wikipedia.org/ [2] https://patents.google.com/ Bumper protecting device for damping and absorbing impact in collision for vehicle [3] https://patents.google.com/ Device for new car anticollision energy-absorbing [4] DESIGN OF MACHINE ELEMENTS by RS.KHURMI from S.CHAND PUBLICATIONS. [5] DESIGN DATA: P.S.G DESIGN DATABOOK OF ENGINEERS from kalaikathir atchagam.. [6] springipedia.com/material-springmaterials.asp [7]www.engineersedge.com/spring_general.htm ISBN-13: 978-1539045540 www.iirdem.org Proceedings of ICEEM-2016-Chennai ©IIRDEM 201617
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