International Journal of Pure and Applied Mathematics Volume 116 No. 14 2017, 327-334 ISSN: 1311-8080 (printed version); ISSN: 1314-3395 (on-line version) url: http://www.ijpam.eu Special Issue ijpam.eu DESIGN AND FRABRICATION OF TILTING SYSTEM

1Venkatesh Babu, 2K.Sathish kumar 1Professor, Department of Mechanical Engineering, 2Asst.Professor, Department of Mechanical Engineering, BIST, BIHER ,Bharath University, Chennai-73 [email protected], [email protected]

Abstract: With the advancement of the transport economy of the truck. Thus there is a surge to find technologies, companies are trying to find ways to find possible methods for improving the mechanism of simpler and cost effective technologies. In today scenario the dump truck hydraulics.This project proposes the dump trucks are used to transportation of materials till idea of using a folding mechanism coupled with now they are operating by hydraulic cylinders.The pneumatics to tilt the trolley of the dump truck. The hydraulic cylinders used for the dump truck tilting system system employs the use of a linkage hinged to are very long so that it can be lifted to a good height. It together and a pneumatic cylinder is attached to the also requires a cylinder with greater diameter so that is hinge. Thus when the pneumatic cylinder works in can bear the weight of the materials in the truck. This the forward direction, the linkages ate stretched and requires a large space to house the cylinder and also the when it is made to return, the linkages get folded cylinder is prone to damages as it has to bear heavy loads. up[9-14]. This not only occupies more space, but also increases the 1.1 Standard dump truck weight of the vehicle, which indirectly affects the fuel economy of the truck. Thus there is a surge to find A standard dump truck is a truck chassis with a possible methods for improving the mechanism of the dump body mounted to the frame. The bed is raised dump truck hydraulics.This project proposes the idea of by a vertical hydraulic ram mounted under the front using a folding mechanism coupled with pneumatics to of the body, or a horizontal hydraulic ram and lever tilt the trolley of the dump truck. The system employs the arrangement between the frame rails and the back use of a linkage hinged to together and a pneumatic of the bed is hinged at the back of the truck. The cylinder is attached to the hinge. Thus when the tailgate can be configured to swing up on top pneumatic cylinder works in the forward direction, the hinges (and sometimes also to fold down on lower linkages are stretched and when it is made to return, the hinges) or it can be configured in the "High Lift linkages get folded up Tailgate" format wherein pneumatic rams lift the gate open and up above the dump body.In the Keywords: Dump truck, kinematic link, pneumatic United States, a standard dump truck has one front pressure, tilting system steering , and one or two rear which typically have dual wheels on each side. Tandem rear axles are virtually always powered in the U.S., far less often in Europe. Most unpowered rear axles can be raised off the pavement, to minimize wear and tear when the truck is empty or lightly loaded, and lowered to become load-bearing when the truck needs the extra support. These are referred to as lift Figure 1. Existing model dump truck axles or drop axles. 1. Introduction The hydraulic cylinders used for the dump truck tilting system are very long so that it can be lifted to a good height. It also requires a cylinder with greater diameter so that is can bear the weight of the materials in the truck. This requires a large space to house the cylinder and also Figure 2. Standard dump truck the cylinder is prone to damages as it has to bear heavy 1.2 Transfer dump: loads[1-8]. A transfer dump is a standard dump truck pulling a This not only occupies more space, but also increases the separate trailer with a movable cargo container, weight of the vehicle, which indirectly affects the fuel

327 International Journal of Pure and Applied Mathematics Special Issue which can also be loaded with construction aggregate — The cross spreads tend to jam and may not work gravel, sand, asphalt, klinkers, snow, wood chips, triple well with coarse materials. mix, etc. The second aggregate container on the trailer ("b" box), is powered by an electric motor, a pneumatic motor or a hydraulic line[26].

Figure 6. Semi trailer bottom dump truck 1.6 Double and triple trailer bottom dump truck: Figure 3. Transfer dump 1.3 Truck and pup: Double and triple bottom dumps consist of a 2-axle tractor pulling one single-axle semi-trailer and an A truck and pup is very similar to a transfer dump. It additional full trailer (or two full trailers in the case consists of a standard dump truck pulling a dump trailer. of triples). These dump trucks allow the driver to The pup trailer, unlike the transfer, has its own hydraulic lay material in windrows without leaving the cab or ram and is capable of self-unloading. stopping the truck. The main disadvantage is the difficulty in backing double and triple units. The specific type of dump truck used in any specific country is likely to be closely keyed to the weight and axle limitations of that jurisdiction. Rock, dirt and other types of materials commonly hauled in trucks of this type are quite heavy, and almost any Figure 4. Truck and pup style of truck can be easily overloaded. 1.4 Semi-trailer end dump truck: 1.7 Side dump truck: A semi end dump is a tractor-trailer combination wherein A side dump truck (SDT) consists of a 3-axle the trailer itself contains the hydraulic hoist. A typical tractor pulling a 2-axle semi-trailer. It has hydraulic semi end dump has a 3-axle tractor pulling a 2-axle semi- rams which tilt the dump body onto its side, trailer. The key advantage of a semi end dump is rapid spilling the material to either the left or right side of unloading. A key disadvantage is that they are very the trailer. The key advantages of the side dump are unstable when raised in the dumping position limiting that it allows rapid unloading and can carry more their use in many applications where the dumping weight in the western United States. location is uneven or off level. In addition, it is almost immune to upset (tipping over) while dumping, unlike the semi end dumps which are very prone to tipping over. It is, however, highly likely that a side dump trailer will tip over if dumping is stopped prematurely. Also, when dumping loose materials or cobble sized stone, the side dump can become stuck if the pile Figure 5.Semi-trailer end dump truck becomes wide enough to cover too much of the trailer's wheels. 1.5 Semi trailer bottom dump truck: A semi bottom dump (or "belly dump") is a 3-axle tractor pulling a 2-axle trailer with a clam shell type dump gate in the belly of the trailer. The key advantage of a semi bottom dump is its ability to lay material in a windrow (a linear heap). In addition, a semi bottom dump is maneuverable in Figure 7. Side dump truck reverse, unlike the double and triple trailer configurations described below. These trailers may be found either of the 1.8 Haul trucks: windrow type shown in the photo, or may be of the "cross Haul trucks are used in large surface mines and spread" type, with the gates opening front to rear instead quarries. They have a rigid frame and conventional of left and right. The cross spread gates will actually steering with drive at the rear wheel. As of late spread gravel fairly evenly the width of the trailer. By 2013, the largest ever production haul truck is the comparison, the windrow gates leave a pile in the middle. 450 metric ton BelAZ 75710, followed by the Liebherr T 282B, the Bucyrus MT6300AC and the

328 International Journal of Pure and Applied Mathematics Special Issue

Caterpillar 797F, which each have payload capacities of valve get the air and passed through the pneumatic up to 400 short tons (363 t; 357 long tons). Most large cylinder depend upon the hand lever directional size haul trucks employ Diesel-electric powertrains, using changed the Diesel to drive an AC alternator or DC 2. Literature Review generator that sends electric power to electric motors at each rear wheel. The Caterpillar 797 is unique for its size, Applications of metal matrix composites in as it employs a to power a mechanical defense, aerospace and light vehicles have been powertrain, typical of most road going vehicles and reported by Rittner (2001). She has concluded that intermediary size haul trucks. Other major manufacturers the scope for MMC in all the above areas were of haul trucks include Hitachi, Komatsu, DAC, Terex and optimistic and suggested further improvement in BelAZ. processes, selection of alloy, selection of reinforcement and selection of components to reduce the cost of end product. Robert (2001) has presented various forms of aluminum alloys and their applications. Based on his survey on the growth of aluminum alloys, he concluded that 32.2 % of the aluminum was Figure 8. Haul trucks consumed in transport industry in different forms. 1.9 Articulated dumper: Foltz and Charles (1991) have presented various matrix alloys, reinforcements and their applications An articulated dumper is an all-wheel drive, off-road in space, defense, automotive and electronic dump truck. It has a hinge between the cab and the dump packaging. box, but is distinct from a semi-trailer truck in that the Surappa(2003) has presented an overview of power unit is a permanent fixture, not a separable vehicle. aluminum matrix composite material systems on Steering is accomplished via hydraulic cylinders that aspects relating to processing, microstructure, pivot the entire tractor in relation to the trailer, rather than properties and applications. Many challenges of rack and pinion steering on the front axle as in a using the metal matrix composites are producing conventional dump truck. By this way of steering, the high quality and low cost reinforcements, trailers wheels follow the same path as the front wheels. developing simple economical and portable non- Together with all-wheel drive and low canter of gravity, it destructive kits to quantify undesirable defects, is highly adaptable to rough terrain. Major manufacturers developing less expensive tools for machining and include Volvo CE, Terex, John Deere and Caterpillar. cutting and also developing re-cycling technology. Details of Components Used • Hand Lever solenoid valve Solenoid valve • Flow control valve • Hose and connectors Figure 9. Articulated dumper • Linkages Proposed model: • Tilt-able Trolley • Frame This project proposes the idea of using a folding mechanism coupled with pneumatics to tilt the trolley of Pneumatic cylinder: the dump truck.A dump truck or trailer for hauling and Cylinder is a device which converts fluid power dumping dry bulk solids conventionally by gravity and into liner mechanical force and motion. These also having the capability of conveying the solids upward cylinders are widely used in industrial pneumatic to a storage facility. The unit includes a container systems. These cylinders are also called as linear mounted to a frame on wheels. A hydraulic ram tilts the motors and reciprocating motors pneumatic container for dumping through a rear outlet. A pneumatic cylinders are designed for a variety of services. conveyor is carried by the frame with an intake at the rear Pneumatic cylinders are designed for a variety of of the container. A gate allows the solids to be dumped services. Pneumatic cylinders transforms the flow conventionally by gravity, or to be blown to a storage of pressured fluid into a push or pull of the piston facility by the pneumatic conveyor. rod since out system uses double acting cylinders we shall see some details about them. The system employs the use of a linkage hinged to The main component of any pneumatic together and a pneumatic cylinder is attached to the hinge. system is the cylinder, which receivers air under Thus when the pneumatic cylinder works in the forward pressure and the pressurized air helps to move the direction, the linkages at stretched and when it is made to piston to and fro. The force acting on the piston return, the linkages get folded up.Hand lever solenoid

329 International Journal of Pure and Applied Mathematics Special Issue will be equal to the product of the pressure of air and the Solenoids may be push type or pull type. The push area of the cylinder. type solenoid is one in which the plunger is pushed The amount of air delivered into the cylinder into the when the solenoid is energized electrically. The cylinder decides the rate of doing work. A cylinder is a pull type solenoid is one in which the plunger is hollow circular section with the top and bottom flange pulled when the solenoid is energized. provided to prevent the leakage of air. The compressed air is used to actuate the piston. In order to move the piston to and fro, the air is supplied to the top and bottom of the cylinder alternatively. Cylinder is mainly classified into two types namely, ➢ Single acting cylinder. ➢ Double acting cylinder. In single acting cylinder, using the spring provided Figure 10. 3/2 Solenoid Valve around the piston rod attains the return stroke, but it is not The name of the parts of the solenoid should be efficient. So, the double acting cylinder is used in which learned so that they can be recognized when called the return stroke is attained using compressed air. upon to make repairs, to do service work or to Double Acting Cylinder: install them. In this the force exerted by the compressed air moves the Working of Solenoid Valve: piston in two directions. They are used partially when the piston is required to perform work not only on the advance movement but also on the return stroke. This principle, the stroke length is unlimited, although bucking and bending must be considered before selecting the particular size of piston diameter, rod length and stroke The solenoid valve has 3 openings. This ensure length. easy exhausting of 3/2 valve. The spool of the 3/2 Double acting pneumatic cylinder: 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 ‗Ps‘ gets connected to ‗Pa‘ and ‗Pr‘ remains closed. Poisition-2 • Stroke length : Cylinder stoker length When the spool is pushed in the inner direction port 160 mm = 0.16 m ‗Pr‘ and ‗Pa‘ gets connected to each other and ‗Ps‘ • Quantity : 1 remains closed. • Seals : Nitride (Buna-N) Hose and Fitings: Elastomer • End cones : Cast iron • Piston : EN – 8 • Media : Air • Temperature : 0-80 º C • Pressure Range : 8 N/m². It is provided for the passage of compressed air Solenoid Valve from the compressor outlet to the operating valve. The directional valve is one of the important parts of a Two separate pipes also connect the operating pneumatic system. Commonly known as DCV, this valve valve with the working cylinder pressure drop is used to control the direction of air flow in the through and airline depends on the flow rate, pipe pneumatic system. The directional valve does this by diameter, and pipe length and pipe geometry. It changing the position of its internal movable parts. can be determined directly for straight pipes of any This valve was selected for speedy operation and to given length. A small chaining bore size can have reduce the manual effort and also for the modification of marked effect on pressure drop, whereas even the machine into automatic machine by means of using a doubling the pipe length, will only result in solenoid valve. A solenoid is an electrical device that doubling the pressure drop.Pressure drop through converts electrical energy into straight line motion and bends and fittings can only be determined by force. These are also used to operate a mechanical empirical tests, since it is specific to the internal operation which in turn operates the valve mechanism. geometry involved. Rigid pipes however are less

330 International Journal of Pure and Applied Mathematics Special Issue manipulated through remain form of bends with air). By one of several methods, an air compressor arrangements increase and variable air have to flow and forces more and more air into a storage tank, the flow itself may be of fluctuating or pulsating nature. increasing the pressure. When tank pressure In this case it is thus normally based on practical reaches its upper limit the air compressor shuts off. recommendation. The compressed air, then, is held in the tank until called into use. The energy contained in the Flow control valve: compressed air can be used for a variety of applications, utilizing the kinetic energy of the air as it is released and the tank depressurizes. When tank pressure reaches its lower limit, the air compressor turns on again and re-pressurizes the tank. 3. Construction & Working Principle Flow Control Valves are fitted to all the distribution Construction: tubes. This valve is made of brass. Both the ends have stepped surface to insert hoses. A handle is provided to Our proposed model ―MODIFIED DUMP TRUCK control the flow of oil in every valve. TILTING SYSTEM‖ need so many raw materials which are mentioned in above chapter. Purpose: For that materials first of all we purchased the raw This valve is used to speed up the piston movement and materials based upon requirement and for that also it acts as a one – way restriction valve which means we‘ve planned to how to buy. After bought we cut that the air can pass through only one way and it can‘t raw materials in required dimensions in precise return back.By using this valve the time consumption is manner by using hand wheel cutting machine. After reduced because of the faster movement of the piston. that we‘ve gone for some rough turning and finishing by using lathe and grinding machines. Tilt-able trolley: After that for assembly purpose we went for welding for permanent joint wherever we require and joined with rivets wherever we require rigidly fixed joints. Up to this, mechanical operations and assembly had done the main thing is need to give connections of pneumatic cylinders to the our model at the last time we had given connections to The trolley is attached to the frame. the pneumatic cylinder and solenoid valve, Material : Mild steel and sheet metal. thereafter we joined that pneumatic cylinder to Length : 120 cm tilting truck to perform it‘s function on tilting truck. Width : 74 cm Load capacity :15 kg (our fabrication model). Working principle Frames The system employs the use of a linkage hinged to together and a pneumatic cylinder is attached to the hinge. Thus when the pneumatic cylinder works in the forward direction, the linkages at stretched and when it is made to return, the linkages get folded up.Hand lever solenoid valve get the air and passed through the pneumatic cylinder depend upon the • Material : Mild steel hand lever directional changed. The linkages are • Length :120 cm those that support the trolley against the frame and • Width : 75 cm they are hinged at the center. Air compressor Block Diagram

Cad diagram:

An air compressor is a device that converts power (using a. Frame an electric motor, diesel or gasoline engine, etc.) into potential energy stored in pressurized air (i.e., compressed

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Applied Engineering Research, v-9, i-22, pp-7749- 7754, 2014. [2] Srinivasan V., Analysis of static and dynamic load on hydrostatic bearing with variable viscosity and pressure, Indian Journal of Science

b. Trolly and Technology, v-6, i-SUPPL.6, pp-4777-4782, 2013. [3] Srinivasan V., Optimizing air traffic conflict and congestion using genetic algorithm, Middle - East Journal of Scientific Research, v-20, i-4, pp- 456-461, 2014. [4] Praveen R., Achudhan M., Optimization of Sample diagram jute composite as a noise retardant material, International Journal of Applied Engineering Research, v-9, i-22, pp-7627-7632, 2014. [5] Raja Kumar G., Achudhan M., Srinivasa Rao G., Studies on corrosion behaviour of borated stainless steel (304B) welds, International Journal Advantage And Application of Applied Engineering Research, v-9, i-22, pp- Advantage: 7767-7772, 2014. • Free from wear adjustment. [6] Ganeshram V., Achudhan M., Design and • Less power consumption moldflow analysis of piston cooling nozzle in • Less skill technicians is sufficient to operate. automobiles, Indian Journal of Science and • It gives simplified very operation. Technology, v-6, i-SUPPL.6, pp-4808-4813, 2013. • Installation is simplified very much. [7] Ganeshram V., Achudhan M., Synthesis and • Less time and more profit. characterization of phenol formaldehyde resin as a • Reduced stroke length of cylinder binder used for coated abrasives, Indian Journal of • Reduced cost in pneumatics Science and Technology, v-6, i-SUPPL.6, pp-4814- • Simple construction 4823, 2013. • Reduced weight of the system. [8] Achudhan M., PremJayakumar M., • Ease of operation Mathematical modeling and control of an Applications: electrically-heated catalyst, International Journal of • It can be used for dump trucks. Applied Engineering Research, v-9, i-23, pp- • It can be used in factories for tilting large equipment. 23013-, 2014. [9] Anbazhagan R., Satheesh B., Gopalakrishnan 4. Conclusion K., Mathematical modeling and simulation of modern cars in the role of stability analysis, Indian This project work has provided us an excellent Journal of Science and Technology, v-6, i-SUPPL5, opportunity and experience, to use our limited knowledge. pp-4633-4641, 2013. We gained a lot of practical knowledge regarding, [10] Udayakumar R., Kaliyamurthie K.P., planning, purchasing, assembling and machining while Khanaa, Thooyamani K.P., Data mining a boon: doing this project work. We feel that the project work is a Predictive system for university topper women in good solution to bridge the gates between institution and academia, World Applied Sciences Journal, v-29, i- industries.We are proud that we have completed the work 14, pp-86-90, 2014. with the limited time successfully. The ―MODIFIED [11] Kaliyamurthie K.P., Parameswari D., DUMP TRUCK TILTING SYSTEM‖ is working with Udayakumar R., QOS aware privacy preserving satisfactory conditions. We are able to understand the location monitoring in wireless sensor network, difficulties in maintaining the tolerances and also quality. Indian Journal of Science and Technology, v-6, i- We have done to our ability and skill making maximum SUPPL5, pp-4648-4652, 2013. use of available facilities. In conclusion remarks of our [12] Kumar J., Sathish Kumar K., Dayakar P., project work, let us add a few more lines about our Effect of microsilica on high strength concrete, impression project work. According to the application. International Journal of Applied Engineering Research, v-9, i-22, pp-5427-5432, 2014. Reference [13] Dayakar P., Vijay Ruthrapathi G., Prakesh J., [1] Arun Kumar N., Srinivasan V., Krishna Kumar P., Management of bio-medical waste, International Analysing the strength of unidirectional fibre orientations Journal of Applied Engineering Research, v-9, i-22, under transverse static load, International Journal of pp-5518-5526, 2014.

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[14] Iyappan L., Dayakar P., Identification of landslide prone zone for coonoortalukusingspatialtechnology, International Journal of Applied Engineering Research, v- 9, i-22, pp-5724-5732, 2014. [15] Swaminathan N., Dayakar P., Resource optimization in construction project, International Journal of Applied Engineering Research, v-9, i-22, pp-5546- 5551, 2014. [16] Swaminathan N., Sachithanandam P., Risk assessment in construction project, International Journal of Applied Engineering Research, v-9, i-22, pp-5552- 5557, 2014. [17] Srividya T., Kaviya B., Effect on mesh reinforcement on the permeablity and strength of pervious concrete, International Journal of Applied Engineering Research, v-9, i-22, pp-5530-5532, 2014. [18] Sandhiya K., Kaviya B., Safe bus stop location in Trichy city by using gis, International Journal of Applied Engineering Research, v-9, i-22, pp-5686-5691, 2014. [19]. Ajona M., Kaviya B., An environmental friendly self-healing microbial concrete, International Journal of Applied Engineering Research, v-9, i-22, pp-5457-5462, 2014. [20] Kumar J., Sachithanandam P., Experimental investigation on concrete with partial replacement of scrap rubber to granite stones as coarse aggregate, International Journal of Applied Engineering Research, v- 9, i-22, pp-5733-5740, 2014. [21] Sachithanandam P., Meikandaan T.P., Srividya T., Steel framed multi storey residential building analysis and design, International Journal of Applied Engineering Research, v-9, i-22, pp-5527-5529, 2014. [22] Srividya T., Saritha B., Strengthening on RC beam elements with GFRP under flexure, International Journal of Applied Engineering Research, v-9, i-22, pp-5443- 5446, 2014. [23] Saraswathy R., Saritha B., Planning of integrated satellite township at Thirumazhisai, International Journal of Applied Engineering Research, v-9, i-22, pp-5558- 5560, 2014. [24] Saritha B., Rajasekhar K., Removal of malachite green and methylene blue using low cost adsorbents from aqueous medium-a review, Middle - East Journal of Scientific Research, v-17, i-12, pp-1779-1784, 2013.

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