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Automated Pneumatic Bumper For Vehicle Safety

Article  in  International Journal of Scientific & Technology Research · February 2020

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 INTERNATIONAL JOURNAL OF SCIENTIFIC & TECHNOLOGY RESEARCH VOLUME 9, ISSUE 02, FEBRUARY 2020 ISSN 2277-8616

Automated Pneumatic Bumper For Vehicle Safety

Sathiskumar S, Dhanush Guru R, Dhavaneeswaran N

Abstract: In automobiles, safety considered as a key thing while designing. The vehicle frontal structure has a bumper, structural parts, which resist and
reduces damages due to vehicle frontal crashes and ensures safety by absorbing the impact. The Pneumatics plays a major role in th e field of
automation and actuation control techniques. The aim is to design and fabricate an automated pneumatic based vehicle bum per system that uses a
sensor with a pneumatic operated bumper in order to avoid car dents and scratches. This system incorporated with an IR transmitter and Receiver
circuit, Control Unit, Pneumatic bumper system. The IR sensor senses the obstacle, which approaches the vehicle. When there is any obstacle closer to
the vehicle (within 2-3 feet), the control signal is given to the electronic circuit which actuates the bumper automatically to absorb the impact and
stopping it from coming too close to the vehicle body. This prevents vehicle damage and ensures the safety of the inmates. This system only actuated
when the vehicle speed is above 30-40 km/hr. This vehicle speed sensed by the proximity sensor and monitored continuously, this signal given to the
control unit, and it actuates the pneumatic bumper system accordingly.

Index Terms: Bumper Design, Electronic Circuit, IR Sensor, Pneumatic Cylinder, Solenoid valve, Vehicle Bumper, Vehicle Safety.

—————————— ◆ ——————————

1. INTRODUCTION tetrahedron). The meshing of the entire geometry results in

The target is a safety system based on the pneumatic 5873 nodes and 2762 elements. Meshing only needed to the
actuation of the vehicle bumper. This system guarantees bumper.
passenger safety within the vehicle. The ultimate objective of
this model is to absorb impact force while a collision takes 2.3 Procedure for Modal Analysis
place without passing force to the car body. It minimizes the In the modal analysis, the number of mode shapes, which we
severity of the damage caused by the vehicle crash and have to extract should be specified. This analysis was done by
improves the safety of vehicle insiders. Several scientists using ANSYS Workbench 11.0. The limit of the frequency
performed different experiments with stroke models and stroke range can be given as an input if required. In this case, only
content. The bumpers absorb the force of impact that is the the first 10 modes are found out and the frequency limit is
cinematic energy generated by the collision during given as 0 to 1000 Hz during the analysis. Then the entire
deformation. Therefore, the material for the bumper is model is meshed into small elements by using fine mesh.
important in restricting the impact force. During meshing the entire model is divided into 10752
elements having 4120 nodes by using a solid185 element.
2 REVIEW OF BUMPER ANALYSIS
2.4 Procedure of Dynamic Analysis in ANSYS
After completing this step the harmonic response analysis
2.1 Procedure for Static Analysis
Code reaches the values of various features, such as mass should be carried out to find out the total deformation, von
mises stress and strain components at various frequencies. In
density, Young's modulus, Poisson ratio, and thermal
conductivity. A further major step is the meshing by selecting this analysis, all loads, as well as the structure’s response,
the part mesh using the C3D10 M element, which allows vary sinusoidally at the same frequency. A typical harmonic
seeds and the global size of as 50 to be finer. The next step in analysis will calculate the response of the structure to cyclic
the process is to integrate the code. This analysis based on loads over a frequency range and obtain a graph of some
the general analysis of the static form. After that, the boundary response quantity versus frequency. “Peak” responses are
conditions and the load must be applied. The choice of the then identified from graphs of response vs. frequency and
area where the motions were arrested also relevant while stresses are then reviewed at those peak frequencies.
applying the boundary condition. Separate meshing and material selections are not necessary
since this harmonic analysis is doing as a continuation of the
2.2 Procedure for Impact Analysis modal analysis which is completed in ANSYS Workbench
Dynamic-explicit type of analysis used for completion of 11.0. In the analysis setting option of the software, we have to
impact analysis in ABAQUS. Then the creation of a datum select the range minimum and maximum of frequency, mode
point at the center of the plate is necessary. For meshing, the frequency range, a number of modes, mode range minimum
seeding is important, in the seeding the entire geometry and maximum, constant damping ratio as 0.01etc. After
divided into small elements having size 35. The type of completing this boundary condition and the load has been
element used is C3D10M (10-node modified quadratic applied in the respective area of the imported model.

____________________________ 3 EFFECT OF THE BUMPER ON CRASHES

• Sathiskumar S is an Assistant Professor in the Department of 3.1 Bumper Test Configurations

Automobile Engineering in Kongu Engineering College, India. On each model vehicle, four different crash tests are carried
PH-9042699880. E-mail: [email protected] out on the contoured, bumper-like barrier. Total simultaneous
• Dhavaneeswaran N is currently pursuing a bachelor’s degree checks for front and rear were performed at 10 km / h and
program in Automobile engineering in Kongu Engineering College, tests for the front and rear corner at 5 km / h. The four tests
India, PH-9865084531. E-mail: [email protected]
were conducted to facilitate reliable and stable interfaces
• Dhanush Guru R is currently pursuing a bachelor’s degree program
in Automobile engineering in Kongu Engineering College, India, PH- between cars in the fleet and to ensure energy absorption. In
7598823775. E-mail: [email protected]
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order to simulate a broader spectrum of impacts on actual speed over 456 mm vehicle journey length that ends with the
road collisions, the barrier heights for the overlap and corner barrier about 150 mm before the vehicle strikes. The velocity
analysis differ. The four checks were conducted by two cars. sensor has its timing module, powered by batteries, inside the
truck, which shows the speed of the truck in kilometers per
3.2 Impact Barrier Specifications. hour. An optical measurement device that assists the speed
The impact barrier with a radius of 3.404 mm and a flat vertical sensor on the vehicle also mounted on the propulsion system.
area of 102 mm has been applied to all bumper tests. The The tool tests the hardware speed at which the vehicle is
barrier is made of a steel plate of 12,5 mm and is mounted to connected to the propulsion system just before the vehicle's
a block of 145,150 kg of enhanced concrete. The upper launch. Before launch, the speed measured over 1,000 mm of
surface of the buffer wall has a metal backstop. The rear end travel length and ends at 500 mm.
also has a 12.5 mm steel platform with a width of 1.524 mm
with a radius of 3.404 mm and a flat vertical surface of 200 4 METHODOLOGY AND DESIGN DEVELOPMENT
mm. The back-end positioned 25 mm from the rear of the
barrier with its middle offset. The impact zone of the barrier 4.1 Methods of Concept Development
face with nylon push-pin rivets is attached to a plastic energy The design is based on the design and development method
absorber. Likewise, the upper and lower flanks with an of the products. Next, it is recognized the need for the
overlying plastic cover are placed on the barrier by slots. Net automatic pneumatic bumper system. The different theoretical
Shape Company manufactures the energy absorber and cover concepts were defined for the development of the process. A
and has a diameter of 152 mm from top to bottom. It has a thorough analysis of the principles is carried out using a
length of 1.524 mm, a thickness of 102 mm and a width of 51 scoring matrix and the best product between various types of
mm. The impact barrier mounted so that the majority of the materials is chosen by the grading process. Finally, for the
bottom of the barrier is 457 mm off the floor for both the front appropriate dimensions, the selected material and design shall
and rear full overlap tests. The centerline of the vehicle be reviewed. The system will be constructed in two
aligned with the centerline of the barrier. The impact barrier dimensions and the system is then modeled in three
installed on the front and rear corner tests so that the bulk of dimensions. For safe layout under deformation stresses the
the lower edge of the barrier to the front is 406 mm from the template is then analyzed.
ground. On effect, the vehicle overlaps the barrier lateral edge
by 15% of the width of the car, measured at the wheel wells in 4.2 Method of Design and Analysis
the corresponding axle— front axle for testing the front corner The system will be designed in two dimensions with
and rear axle for testing the rear corner. AUTOCAD and modeled with the version software
SOLIDWORKS–2016. In different conditions of impact force,
3.3 Photography stress rates and the deformation, ANSYS technology will then
Tests are recorded using at least one overhead and one digital be used to evaluate the individual components for protection.
image imager mount (500 fps) or film camera (125 fps) and
the Sony Betacam video camera mounted on the floor (30 4.3 Method of Controlling Pneumatic Bumper
fps). After the test is done, a digital still camera is used to Our system is a sensor-based system that is used to detect if
document any resulting damage. The vehicle is photographed an object is just 2-3 feet away. If any object comes close to the
More closing photographs are taken with ready visible system, it is sensed by the IR sensor. Then the signal is sent
damage; photographs are also taken in order to record to the microprocessor which in turn operates the relay. Then
concealed damage during the wear down / assessment the relay actuates the solenoid-operated Directional Control
process. Valve, the air from the reservoir tank enters into the pneumatic
cylinder through a flow control valve. Then the pneumatic
3.4 Damage Estimates cylinder pushes out the bumper to absorb the collision impact
The method of damage assessment is performed in a repair and to stop coming too close to the vehicle body. It retracts
shop. In general, each bumper is removed and inspected for when the risk it from subsides. All the electronic circuits and
hidden damages. Due to industry standard assessment pneumatic components are mounted on a frame with
technologies, Damage repair estimates are performed and supporting bed having four wheels that resemble the vehicle. If
documented by Audatex, a Solera company, as part of a we force any object to this vehicle system, the bumper
computerized system. Audatex offers an average labor rate for extends to resist and retracts after the risk subsides.
the repair of bodywork and finishing used in its client's actual
country figures for the most recent calendar year trimesters for
the hourly work rate as calculated in the reports. This average
rate is rounded to the closest dollar and used for labor costs
calculations. The prices of paint and related materials are also
based on the average price used by Audatex consumers over
the last quarter and are directly commensurate with the overall
time to finish that calculation.

3.5 Impact of Speed Measurement

Impact speed measured by means of an optical speed sensor Fig 1. IR sensor detecting object
on the side of the vehicle to detect reflective strips of the floor
in the hall crash. 456 mm apart on the front edges of the
plates. The impact rate recorded, therefore, is the average

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material is its excellent machinability. The most important

4.3 Concept Generation properties of steel are great formability and durability. The
The automated pneumatic bumper system is designed and density of the material is 7850 kg/m3and young’s modulus is
developed using the “Concept Development process” method 206GPa and yield stress is 318 MPa. The mild steel bumper is
as shown in Fig 2. Concept generation is the process of undergoing impact force and stress concentration analysis
introducing new ideas based on the inputs and complaints using ANSYS software.
provided by the customers. The four steps involved in concept 5.2 Concept 2:
generation are listed below. Aluminum alloy is in which aluminum is the predominant
• Compressor – compressor used to create air and it is metal. The typical alloying elements are copper, magnesium,
stored in the reservoir tank manganese, silicon, and zinc. The most cast aluminum alloy is
• IR sensor – IR sensor used for detects the object Al-Si where the high levels of silicon (4-13%). aluminum alloy
• Solenoid – solenoid actuates the DCV is widely used in engineering structures and components
• Pneumatic cylinder – it is used to extend and retract where lightweight or corrosion resistance. Aluminum alloy
the bumper much less-flammable contains a very high percentage of
magnesium. Aluminum alloy has a tensile strength, ductile,
formability, workability and corrosion résistance. Aluminum
alloy has a tensile strength of 220 MPa and an elastic modulus
of 80GPa and it has a low weight. The Aluminium alloy
bumper is undergoing impact force and stress concentration
analysis using ANSYS software.

5.3 Concept 3:
A thermoplastic or thermosoftening plastic is a plastic material,
a polymer, which becomes pliable above a specific
temperature. Most thermoplastics have a high molecular
weight. The polymers chains associate through intermolecular
forces, which weaken rapidly with increased temperature, yield
a viscous liquid.it is manufactured by injection molding,
compression molding, and extrusion. Engineering plastics
Fig 2. Steps involved in Concept development Process include polycarbonate and polyamides, acrylonitrile butadiene
styrene used for car bumpers and dashboards. Engineering
5 BUMPER DESIGN plastics are gradually replaced by traditional materials in many
The design was slightly varied from the conventional bumper applications.
design. The circular channels were used in the design, which
is uncommon among the commercially available in the vehicle 5.4 Description of Selected Bumper Material
bumper. The diameter of the channel used was 25 mm. The From the above studies, it is clear that the use of automated
thickness used was around 3 mm. The front length of the pneumatic actuating extendable and retractable bumper of
bumper is 156 cm. The bumper is modeled using glass mat reinforced thermoplastic is a very good solution for
SOLIDWORKS software and the end product was reviewed. the enhancement of safety in a vehicle and to reduce
damages due to collision in vehicle accidents. The designed
bumper has a diameter of 25mm and a thickness of 3mm.
Glass mate thermoplastic replaced material usage in the
automotive vehicles. using glass mate thermoplastic
comparatively it has equal strength like aluminum and steel.
GMT is a weightless material.GMT in thin sheets of 3mm
thickness with various fibers mates like continuous, chopped,
randomly laid that all yield specific characteristics. GMT
material has 12 GPa young’s modulus and the Poisson ratio of
0.41, a density of 1280 kg/m3. The bumper beam supporting
structure composed of a kelvin Voigt spring dashpot system.
GMT damping parameter of c=0.015.the above Table III
shows that GMT is about 85% and 77% respectively
lightweight and exceeding yield strength.

Fig 3. 3-D modeling of bumper 6 DESIGN ANALYSIS OF BUMPER SYSTEM

5.1 Concept 1: 6.1 Load Analysis
The pumper first material is mild steel. It’scontaining During vehicle collision, the impact force is calculated and
approximately 0.05 – 0.25% carbon making it malleable and then the calculated impact force is applied on the bumper
ductile. Mild steel has a relatively low tensile strength, but it is materials. Impact force calculation mass of the vehicle and
cheap and easy to form. Surface hardness can be increased vehicle initial and final velocity are considered.
through carburizing. Mild steel also has easy machinability. So
the main reason behind using mild steel is manufacturing

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6.2 Impact force

For calculating the impact force of the vehicle mass of the
vehicle consider as 20kg and accidents are happen more than
30 km/hr. so vehicle speed is considered as 35 km/hr.

Mass of the vehicle = 20 kg (approx)

Acceleration = final velocity – initial velocity/time
Vehicle speed = 35 km/hr
When it hit an object, coming to a complete stop in 0.05
seconds = 0 - 9.72 /0.05
= - 194.44m/s2
Force = Mass*Acceleration
= 194.44*20
Impact Force = 3888.8N
Fig 6. Aluminum Alloy Deformation
6.2 Mild Steel Bumper Analysis
The impact force of 3888.8 N applied in the steel bumper to 7 BUMPER DRIVING COMPONENTS
deformation and stress concentrations are noted. During
vehicle collision, mild steel bumper get more deformation and 7.1 Pneumatic Cylinder
very high-stress concentration The cylinder is a Double-acting cylinder one, which means that
the air pressure operates forward and backward strokes. The
air from the compressor is passed through the 5/2 solenoid
valve which controls the pressure to the required amount by
adjusting its knob. A pressure gauge is attached to the air
storage tank for showing the pressure.

Fig 4. Mild steel deformation

Fig 7. Aluminum Alloy Stress concentration

Pneumatic cylinder pulling capacity:

Force = Pressure x Area
Air compressor of 3 bars pressure.
Pneumatic cylinder piston diameter = 25mm
Area of the piston = ᴫR2
Fig 5. Mild steel stress concentration = 490.87 mm2
Total thrust force = 490.87 x 10-6 m2 x 3 x 105 Nm2
6.3 Aluminium Alloy Bumper Analysis = 140.36 N
The impact force of 3888.8 N applied in the steel bumper to Load = 140.36/9.81
deformation and stress concentrations are noted. During = 15 kg capacity of pull force.
vehicle collision, aluminum alloy bumper get less deformation The 25mm diameter of pneumatic cylinder pulling up to 15kg
and stress concentration also less
7.2 Direction Control Valve
The directional valve is one of the important parts of a
pneumatic system. 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.

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TABLE- 1
COMPONENT SPECIFICATION 8.3 Program
Type 5/2 The below program is used to control the bumper actuation.
Voltage 12 DC
Power 6VA int a = A1;
int y;
Working pressure 1.5 -10 Bar
int relay = 13;
inthallsensor = 2;
volatile byte counter;
unsigned int rpm;
unsigned long passedtime;
void isr()
{
counter++;
}
void setup() {
Serial.begin(9600);
pinMode(A1, INPUT);
Fig 8. 5/2 DCV pinMode(relay , OUTPUT);
attachInterrupt(0, isr, RISING);
8 FABRICATION WORK pinMode(hallsensor, INPUT); counter = 0;
rpm = 0;
8.1 Mechanical components passedtime = 0;}
Automated pneumatic bumper mechanical components are void loop() {
bumper fabrication and cylinder bed. The bumper is fabricated
delay(100);//Update RPM every second
by using the bending machine and welding process. The
detachInterrupt(0); //Interrupts are disabled
bumper is made by using a glass mate thermoplastic material
.cylinder bed is used for mounting the pneumatic cylinder. rpm = 60*1000/(millis() -passedtime)*counter;
passedtime = millis();
counter = 0;
Serial.print("RPM=");
Serial.println(rpm); //Print out result to monitor
attachInterrupt(0, isr, RISING);
y = analogRead(A1); Serial.print(y); Serial.print("\n");
if (y>200)
if(rpm==0){ digitalWrite(relay, HIGH );} else{
digitalWrite(relay, LOW );}

Fig 9. Pneumatic Cylinder Bed 9 CONCLUSION

Thus, the proposed project pneumatic bumper system is
8.2 Electric work fabricated and developed as per the design and calculations
• Arduino Uno are done for this system. The pneumatic bumper is to reduce
• IR sensor vehicle damage during a vehicle collision.
• Hall sensor
McGraw Hill Publications, 1999.
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International Journal of Innovative Technology and

Exploring Engineering, ISSN: 2278–3075 (Online),
Volume-9 Issue-1, November 2019, Page No. 126-133

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