DESIGN AND CONSTRUCTION OF

CHILD RESCUE PNEUMATIC SYSTEM

A PROJECT REPORT

Submitted by

GNANAPRAKASH. T 721714114029
GOKUL. K 721714114030
GOKULAKRISHNAN. K 721714114031
GOPALAKRISHNAN. S 721714114034
 in partial fulfillment for the award of the degree
of
BACHELOR OF ENGINEERING

in

MECHANICAL ENGINEERING

P. A. COLLEGE OF ENGINEERING AND TECHNOLOGY

POLLACHI - 642 002

ANNA UNIVERSITY :: CHENNAI 600 025

APRIL 2018

ANNA UNIVERSITY : CHENNAI 600 025

BONAFIDE CERTIFICATE

Certified that this project report “DESIGN AND CONSTRUCTION OF CHILD

RESCUE PNEUMATIC SYSTEM” is the bonafide work of T. GNANAPRAKASH
(721714114029), K.GOKUL (721714114030), K. GOKULAKRISHNAN
(721714114031), S. GOPALAKRISHNAN (721713114034) who carried out the
project report under my supervision.
SIGNATURE SIGNATURE

Dr. T. VARUN KUMAR, M.E., Ph.D., Mr. I. AKILAN, M.E.,

HEAD OF THE DEPARTMENT SUPERVISOR

Associate Professor, Assistant Professor,
Department of Mechanical Engineering, Department of Mechanical Engineering,
P. A. College of Engineering and P. A. College of Engineering and
Technology, Pollachi - 642 002. Technology, Pollachi - 642002.
 Submitted for the university project viva-voce held on ……………….

Internal Examiner External Examiner

ACKNOWLEDGEMENT

With genuine humility, we are obediently thankful to God almighty praise and glory is
to him, for all his uncountable bounties and guidance, without which, this work would have
never been a reality.

We wish to record our sincere thanks to our respected Chairman Dr. P.

Appukutty, M.E., F.I.E., F.I.V., for his encouragement towards our project activities and
extending all the facilities needed to carry out this project.

We wish to record our sincere thanks to Dr. T. Manigandan, M.E., Ph.D., Principal, P.
A. College of Engineering and Technology for extending all the facilities needed to carry
out this project.

We express our deep and sincere thanks to Dr. V. Ramalingam, M.E., Ph.D., Dean of
Mechanical Department, who has been a spark for enlightening our knowledge.

We express our sincere thanks to Dr. T. Varun kumar, M.E., Ph.D., Associate
Professor and Head of the Department of Mechanical Engineering for his keen interest
shown and facilities provided to complete this project.

iv
 We express our sincere thanks to Mr. I. Akilan, M.E., Assistant Professor, Mechanical
Department, for his valuable guidance, keen interest shown and facilities provided to
complete this project.

We express our sincere thanks to our faculty coordinator Mr. M. Jayaraj, M.E., for his
valuable support and constant motivation during the course of this project.

We wish to express our gratitude to all teaching and non-teaching faculty members of
Department of Mechanical Engineering for their valuable support.

ABSTRACT

This project is generally based on the child rescue in the bore well. Now a days

child falls into an abandoned bore well, which is left uncovered and get trapped.

Normal operation to rescue the child is to pit a dig nearer to the bore well. That logic is

difficult and also risky to rescue the trapped child. It takes extra time to recover the

child from the bore well. In this project, the pneumatic system moves inside the

uncontrolled bore well. The system consists of camera, holding clamps, pneumatic

cylinders and solenoid valves. The camera is connected with PC to identify the motion

and position of the child. The holding clamps are actuated to hold the child by the

pneumatic cylinder. This kind of system can release trapped baby from the bore well

securely within lesser time. It will be a light weight mechanism that will go down into

the bore well pipe and hold the trapped body systematically. This assembly will be

supported by a rope roller drive, stand and all necessary accessories. A lot of other

v
hassles will also be avoided by this alternative technique. This pneumatic type machine

can rescue trapped body from bore well in minimum amount of time and life safe.

TABLE OF CONTENTS

vi
CHAPTER NO. TITLE PAGE NO.

ABSTRACT i

TABLE OF CONTENTS ii

LIST OF FIGURES v

LIST OF TABLES vii

1 INTRODUCTION 1-4
1.1 INTRODUCTION 1
1.2 HISTORY 2
1.3 EXISTING METHODS 3
1.4 PROPOSED METHOD 4

2 LITERATURE REVIEW 5-7

3 METHODOLOGY 8-9
3.1 AREA OF PROJECT SELECTION 8
3.2 LITERATURE SURVEY 9
3.3 PROBLEM IDENTIFICATION 9
3.4 DESIGN AND MODELING 9
3.5 FABRICATION PROCESS 9
3.6 RESULT ANALYSIS 9
3.7 COMPARING WITH EXISTING 9
METHODS
3.8 CONCLUSION 9

7
4 DESCRIPTION OF COMPONENTS 10-21
4.1 DC MOTOR 10
4.2 CAMERA 13
4.3 PULLEY 13
4.4 RELAY 14
4.5 COMPRESSOR 15
4.6 PNEUMATIC CYLINDER 16
4.7 SOLENOID VALVE 19
4.8 CONTROL UNIT 21

5 DESIGN CALCULATION 22-35

5.1 FRAME 22
5.1.1 Vertical support 22
5.1.2 Horizondal support 23
5.2 PNEUMATIC CYLINDER 24
5.2.1 Theoretical air consumption 26
calculation
5.2.2 Selection of Standard 27
Pneumatic cylinder
5.3 ROPE 28
5.4 WORM AND WORM GEAR 29

6 DESIGN AND MODELING 31-33

6.1 2D-DESIGN 31
6.2 3D-PART MODELING 31
6.2.1 Frame 31
8
 6.2.2 Clamp set-up 32
6.2.3 Pneumatic cylinder set-up 32
6.2.4 Worm and worm gear 33
6.3 3D-ASSEMBLY MODELING 33

7 FABRICATION PROCESSES 34-41

7.1 MANUFACTURING PROCESS 34
7.1.1 Lathe operations 34
7.1.2 Drilling 35
7.1.3 Metal cutting 37
7.2 ASSEMBLY 39
7.2.1 Welding 39
7.2.2 Soldering 40

8 WORKING PROCEDURE 42

9 RESULT AND DISCUSSION 43

10 COST OF ESTIMATION 44

11 WORKING MODEL OF CHILD 45

RESCUE SYSTEM
11.1 PHOTOGRAPHS 45
12 CONCLUSION 46

REFERENCES 47-4

LIST OF FIGURES

9
FIGURE NO TITLE PAGE NO

4.1 DC Motor 10
4.2 3D modeling of DC motor 11
4.3 DC motor rotation 12
4.4 3-Pole DC motor 12
4.5 Air compressor 15
4.6 Pneumatic cylinder 16
4.7 Working of pneumatic cylinder (Forward 17
stroke)
4.8 Working of pneumatic cylinder (Forward 17
stroke)
4.9 3D modeling of pneumatic cylinder 18
4.10 Working of Solenoid valve 19
4.11 3D-modeling of solenoid valve 20
6.1 2D Design of child rescue system using 31
AutoCAD 2007 software Frame
6.2 3D Modeling of Frame 31
6.3 3D Modeling Clamp set-up 32
6.4 3D Modeling of pneumatic cylinder set- 32
6.5 up 3D Modeling of Worm gear set-up 33
6.6 Assembled Model 33
7.1 Lathe Machine 34
7.2 Lathe Operation 35
7.3 Drilling Machine 36
7.4 Drilling Operation 37
7.5 Portable metal cutting 38
10
7.6 Metal Cutting Machine 38
7.7 Weld 39
7.8 Welding process 40
7.9 Soldering 41
7.10 Soldering process 41
11.1 Assembled view 1 45
11.2 Assembled view 45

11
 LIST OF TABLES

TABLE NO TITLE PAGE NO

5.1 Standard pneumatic cylinder size 28

10.1 Cost Estimation 44

12
 CHAPTER -1

INTRODUCTION

1.1 INTRODUCTION

A pneumatic controlled system to save a child trapped in a borewell. Recently,

many accident reports of children (and even adults) falling in open bore-wells have
appeared in the print and the electronic media. Very few of the victims have been
saved in such accidents. In some of these cases the dead body of the subject could
not be collected easily. Even if rescued late, most victims were reportedly injured.
To overcome such problems of these rescue operations, we have an alternative
(feasible) proposal. We are developing a pneumatic system that can take out the
trapped body in systematic way. A video camera to observe the actual situation
closely and continuous interaction with the sufferer could also be attached. It will be
a light weight machine that will go down into the bore well pipe and hold the
trapped body systematically. This machine assembly will be supported by a cable
wire and this will be controlled and supported by a gear assembly, a stand and all
necessary accessories.
In this alternative scenario, there will be no requirement of digging any hole
parallel to the bore-well. The remotely controlled robot will go down the bore well
and perform the action. A lot of other hassles will also be avoided by this alternative
technique.
Technologies are developed for various human needs and applications. But,
for these borewell accidents, there is no projects developed in a successful manner.
This project makes some better chances to rescue the child from borewells.

13
1.2 HISTORY

The expected number of wells and bore wells in India is now around twenty-
seven million, with bore wells accounting for more than 50 percent. Growing water
scarcity is being standard as the most important problem in India. Since the water
level is decreasing day by day so more peoples are affected. Bore wells are
constructed to fulfill the needs. These bore wells are left unclosed after finding that
ground water is not abundant in the place.
Bores yielded water and subsequently got depleted are left uncovered. The
bore wells in turn have started to take many innocent lives. Small children without
noticing the bore well slip inside and get trapped. There is no proper technique to
rescue method for such accidents. In most cases a parallel hole is dug up and then a
horizontal path is made to reach to the baby. It takes nearly 30 hours to dig the
parallel pit, by that time the child would have died. It is a time taking process, and
also risky in various ways. Moreover, it requires lots of energy and expensive
resources which are not easily available everywhere. There is possibility of injuries
to the child inside the well.
In most of the cases the child rescue operation was ended with failure. To lift
the child out the narrow confines of the bore well is also not very easy. In some other
methods a kind of hooks and grapes is employed to hold the child’s clothes and body.
This may cause wound on the body of the child. After studying all the cases we found
a serious issue, and to make a such pneumatic machine which can go through the
trapped bore well without any support and grasp the trapped body at least minimum
time. With this system, there is no chance of damaging human body and other minor
damages.

14
1.3 EXISTING METHODS
The common method used to find the depth of child is with the help of a rope.
In normal rescue operation carried out by the army, a pit is initially dug parallel to
the borewell, and a horizontal path to the location of the child is caved through. This
is a highly time consuming process as well as risky to both, the rescuer and rescuee.
The soil has to be stiff since loose structure will result in the cave collapsing.
Moreover, it involves a lot of energy, manpower and expensive resources which are
not easily available everywhere. Throughout the entire process, there is a high risk
factor that surrounds injury to rescuer or rescuee. Also, the body may trap further in
the debris and jeopardize the rescue operation.
Robots are designed to help the human operators in the rescue mission.
Rescue team normally follows the parallel pit process to save the child. First the
team will find the depth of the child in the bore well by using rope. Earth moving
vehicles are used to dig the parallel pit near the bore hole. It takes long time. At the
time the child would have died due to lack of oxygen. Due to the lack of
visualization the rescue team faces many difficulties.
In another method a light weight machine goes inside the bore well pipe and
holds the trapped body systematically. The robot is operated through a PC using
wireless Zigbee technology. When the user presses the button from the keyboard of
the PC, the data related to that particular button is sent through Zigbee. If LDR
detects the darkness, LED gets ON. The data received by the Zigbee in the robot and
fed to the Microcontroller. According to the information received by a
microcontroller (PIC 16F877A), the robotic arm will perform its movement. DC
motor is used in robotic arm. Another proposed method has used ARM8 instead of
the PIC microcontroller.

15
1.4 PROPOSED METHOD
The simple system that we are proposed to rescue the child consists of four
pneumatic cylinders with solenoid valve which are operated by air compressor. The
clamps hold the child when the pneumatic cylinders are operated. This system
moves inside the borewell with the help of Rope drive. Web camera is used to
identify the position of child. Hence its is easier to rescue the child from borewell
with in a short period of time. Thus, this method is used ton rescue the child in the
most comfortable manner.
Pneumatics system should replace humans in the activities of performing
repetitive and dangerous tasks which humans prefer not to do due to size limitations,
extreme environments, etc. It will also perform various life-saving operations for the
victims such as video camera to observe the actual situation closely and continuous
interaction with the sufferer could also be possible

16
 CHAPTER-2

LITERATURE REVIEW

The designing of a robot for rescuing a child from the bore well. This robot is
capable of moving inside the bore well. This Smart Child Rescue System consists of
PIR sensors which help to sense only humans irrespective of the external conditions.
In this system Raspberry pi is used which is costly than Arm microcontroller. It
requires more peripherals. [1]

This is the rescue operations without human intervention. The robot can adjust
its legs according to the pipeline dimensions. The robot consists of power supply,
actuators, and dc motor, servo motor. The child position is captured from bore well
with Camera module and monitored on PC. The ultrasonic sensor interfaced with
arduino. The arduino uses a microcontroller not an application processor, so can not
run any operating system on it. [2]

The diameter of the narrow borewell for any adult person because light goes
dark inside it, the rescue task is challenging. The robotic system attaches a harness to
the child using pneumatic arms for picking up. A teleconferencing system is also
attached to the robot for communicating with the child. [3]

The first step to visualize the child this is done by lowering the high resolution
Camera inside the bore well. With the aid of high resolution camera the location
(depth) and position of the child can be determined. It is mechanical based project so
this system doesn’t have any intelligence and it is non automized system. [4]

The design of two micro‐robotic structures in an effort for assisting the

detection of human under debris and rescue them. These microstructures will play
complementary role to existing larger robotic structures, which mainly perform
different rescue tasks. Here the micro‐robot, called This as, is under development by

17
a research team consisted of researchers from the ATRC‐WSU (micro‐design,
software), the Ohio State University (micro‐antennas). [5]

A wireless sensor fusion system in the mechanical gripper robotic arm to

assist the rescue operation and paramedical team effectively. Multiple sensors are
interfaced to the wireless sensor fusion system to acquire the important parameters
such as humidity, temperature, CO, and other gaseous levels from the borewell to
monitor the condition of the child inside the bore well. In this system pc
microcontroller is used which has low speed operation than Arm. [6]

The factors influencing the accuracy of detection of obstacles using Ultrasonic

Sensors in our local navigation system for the visually impaired. The findings of this
paper serve as the basis for design and technical set up of the obstacle detection
system. The distance between the object and the sensor, movement of the object or
the sensor, change in temperature or pressure have an influence on the accuracy of
the detection of obstacles as well as the estimation of distance between the obstacle
and the user. Thus, placing and detecting the obstacles at an optimized distance
becomes crucial to ensure safety of the visually impaired user. The results show that
inaccuracy in distance estimation between user and the obstacles is considerably low
thus indicating US as an optimum choice for detecting obstacles in the local
navigation system. However, further improvement in the distance estimation and
obstacle detection can be achieved by using a combination of other sensors along
with the US sensors. [7]

Battery management for rescue robots is summarized in this paper as a

guideline for new developers. This paper covers the topics of power consumption,
battery selection, battery charging/ discharging and battery maintenance. But this
system requires more hardware and also its design is complicated so this system is
costly. [8]

18
 Designing a system Ultrasonic sensor is a component of detecting the
distance. STC89C52 SCM (single chip machine) is a control component. According
to the design requirements and tasks, the choice in the program must be paid
attention to the operation and price. There are many tools and methods in measuring
distance in present, such as laser ranging, infrared ranging, ultrasonic ranging and
more advanced satellite ranging, and so on. The advantage of laser ranging is the
good color, strong direction, very long distances measurement. Its disadvantage is
the blind spot in 15 meters. The advantage of infrared ranging is long distance
measurement. Measurement distance can reach to 1-5 kilometers. Its disadvantage is
higher price than ultrasonic ranging. [9]

The framework of rescue robot is composed of rescue mechanism, anchorage

set, hoist set, manipulator, frame work, control and communication system. The
robot system can undertake the rescue tasks for small caliber wells, whose diameters
can change from 1m to 0.3m by replacing some mechanisms. This system can be
used for small caliber well rescue system. It requires more hardware. [10]

Based on above papers, design calculations of pneumatic cylinder and worm

gear are obtained. The specifications and characteristics are known. The fabrication
procedures for the child rescue pneumatic system are determined and future
enhancements are also obtained.

19
 CHAPTER-3

METHODOLOGY

The construction of child rescue pneumatic system is based on the following

methodology,

AREA OF PROJECT SELECTION

LITERATURE SURVEY

PROBLEM IDENTIFICATION

DESIGN AND MODELING

FABRICATION PROCESS

RESULT ANALYISIS

COMPARING WITH EXISTING

METHODS

CONCLUSION

20
3.1 AREA OF PROJECT SELECTION
The Project is selected based on the problem arises during rescue operation of
child in borewell accident by avoiding the traditional or common method and
introducing a new system to rescue the child.
3.2 LITERATURE SURVEY
The existing child rescue robots and machines and their drawbacks area
analysed through the literature survey of the related projects.

3.3 PROBLEM IDENTIFICATION

The problems in the existing method of child rescue are identified and are
considered to modify the design of child rescue system.

3.4 DESIGN AND MODELING

The existing design is modified or new design is included with safe
dimensions by calculating the parameters of all components that should withstand
the maximum stress arises during the rescue operation and to perform the child
rescue operation in the easier manner.

3.5 FABRICATION PROCESS

The working model of child rescue system is manufactured by different
fabrication process based on the predefined design.

3.6 RESULT ANALYSIS

The result is analysed from the performance of operation to rescue the child
by considering safety, time and other factors.

3.7 COMPARING WITH EXISTING METHODS

21
 The performance is compared with the existing methods of child rescue
system and advantages are listed out.

3.9 CONCLUSION
Thus, the project makes the change to rescue the child in the simplest manner.

22
 CHAPTER-4

DESCRIPTION OF COMPONENTS

4.1 DC MOTOR

The electric motor, operation is based on simple electromagnetism. A current-

carrying conductor generates a magnetic field; when this is then placed in an
external magnetic field, it will experience a force proportional to the current in the
conductor, and to the strength of the external magnetic field. As you are well aware
of from playing with magnets as a kid, opposite (North and South) polarities attract,
while like polarities (North and North, South and South) repel. The internal
configuration of a DC motor is designed to harness the magnetic interaction between
a current-carrying conductor and an external magnetic field to generate rotational
motion (Fig: 4.1).

Let's start by looking at a simple 2-pole DC electric motor (here red represents a
magnet or winding with a "North" polarization, while green represents a magnet or
winding with a "South" polarization).

Fig: 4.1 DC motor

23
 Every DC motor has six basic parts -- axle, rotor (armature), stator, commutator,
field magnet(s), and brushes. In most common DC motors, the external magnetic
field is produced by high-strength permanent magnets. The stator is the stationary
part of the motor -- this includes the motor casing, as well as two or more permanent
magnet pole pieces. The rotor (together with the axle and attached commutator)
rotates with respect to the stator. The rotor consists of windings (generally on a
core), the windings being electrically connected to the commutator. The above
diagram shows a common motor layout -- with the rotor inside the stator (field)
magnets.

The geometry of the brushes, commutator contacts, and rotor windings are such
that when power is applied, the polarities of the energized winding and the stator
magnet(s) are misaligned, and the rotor will rotate until it is almost aligned with the
stator's field magnets. As the rotor reaches alignment, the brushes move to the next
commutator contacts, and energize the next winding. Given our example two-pole
motor, the rotation reverses the direction of current through the rotor winding,
leading to a "flip" of the rotor's magnetic field, driving it to continue rotating. DC
motor is modeled (Fig: 4.2).

Fig: 4.2 3D Modeling of DC motor

24
 In real life, though, DC motors will always have more than two poles (Fig: 4.3)
(three is a very common number). In particular, this avoids "dead spots" in the
commutator. You can imagine how with our example two-pole motor, if the rotor is
exactly at the middle of its rotation (perfectly aligned with the field magnets), it will
get "stuck" there. Meanwhile, with a two-pole motor, there is a moment where the
commutator shorts out the power supply. This would be bad for the power supply,
waste energy, and damage motor components as well.

Fig: 4.3 Rotation of DC motor

So since most small DC motors are of a three-pole design (Fig: 4.4), let's tinker
with the workings of one via an interactive animation.

25
 Fig: 4.4 3-Pole DC Motor

A few things from this -- namely, one pole is fully energized at a time (but two
others are "partially" energized). As each brush transitions from one commutator
contact to the next, one coil's field will rapidly collapse, as the next coil's field will
rapidly charge up (this occurs within a few microsecond). We'll see more about the
effects of this later, but in the meantime you can see that this is a direct result of the
coil windings' series wiring:

4.2 CAMERA
A camera is a device used to capture images, either as still photographs or as
sequences of moving images (movies or videos). The term comes from the Latin
camera obscura for "dark chamber" for an early mechanism of projecting images
where an entire room functioned as a real-time imaging system; the modern camera
evolved from the camera obscura.
Cameras may work with the light of the visible spectrum or with other
portions of the electromagnetic spectrum. A camera generally consists of an enclosed
hollow with an opening (aperture) at one end for light to enter, and a recording or
viewing surface for capturing the light at the other end. Most cameras have a lens
positioned in front of the camera's opening to gather the incoming light and focus all
or part of the image on the recording surface. The diameter of the aperture is often
controlled by a diaphragm mechanism, but some cameras have a fixed-size aperture.

4.3 PULLEY
A pulley is a wheel with a groove along its edge, also called a sheave, for
holding a rope or cable. Pulleys are usually used in sets designed to reduce the
amount of force needed to lift a load. The same amount of work is necessary for the
load to reach the same height as it would without the pulleys. The magnitude of the
26
force is reduced, but it must act through a longer distance. The effort needed to pull a
load up is roughly the weight of the load divided by the number of wheels.
The pulleys and lines are weightless, and that there is no energy loss due to
friction. It is also assumed that the lines do not stretch. With this assumption, it
follows that, in equilibrium, the total force on the pulley must be zero. This means
that the force on the axle of the pulley is shared equally by the two lines looping
through the pulley. The lines are not parallel, the tensions in each line are still equal,
but now the vector sum of all forces is zero.

4.4 RELAY

A relay is an electrically operated switch. Current flowing through the coil of

the relay creates a magnetic field which attracts a lever and changes the switch
contacts. The coil current can be on or off. So relays have two switch positions and
they are double throw (changeover) switches. Relays allow one circuit to switch a
second circuit which can be completely separate from the first. The link is magnetic
and mechanical. The coil of a relay passes a relatively large current, typically 30mA
for a 12V relay, but it can be as much as 100mA for relays designed to operate from
lower voltages. The maximum output current for the popular 555 timer IC is 200Ma.

Relays are usually SPDT or DPDT but they can have many more sets of
switch contacts, for example relays with 4 sets of changeover contacts are readily
available. Most relays are designed for PCB mounting but you can solder wires
directly to the pins providing you take care to avoid melting the plastic case of the
relay. The animated picture shows a working relay with its coil and switch contacts.
This lever moves the switch contacts. There is one set of contacts (SPDT) in the
foreground and another behind them, making the relay DPDT.

27
4.5. COMPRESSOR
Compressor is the air producing machine. They collect the airs from the
atmosphere are in the running of machine are engine. Air compressors are utilized to
raise the pressure of a volume of air. Air compressors are available in many
configurations and will operate over a very wide range of flow rates and pressures.
Compressed air was expelled by primitive man to give glowing embers sufficient
oxygen to allow them to flare up into a fire. During the compression process, the
temperature increases as the pressure increases. This is known as polytypic
compression.
Selection of the air compressor is only the first step in designing an efficient
and reliable compressed air system (Fig: 4.5). The air exiting the compressor is
saturated with moisture and will have compressor lubricants (lubricated compressors
only).

Fig: 4.5 Air compressor

28
4.6. PNEUMATIC CYLINDER

Pneumatic cylinders (Fig: 4.6) impart a force by converting the potential

energy of compressed gas into kinetic energy. This is achieved by the compressed
gas being able to expand, without external energy input, which itself occurs due to
the pressure gradient established by the compressed gas being at a greater pressure
than the atmospheric pressure. This air expansion forces a piston to move in the
desired direction.

Fig: 4.6 Pneumatic cylinder

Pneumatic cylinders can be moved both inwards and outwards by compressed

air. Cylinders of this type are called double-acting cylinders.
Cylinders also exist which can only be moved pneumatically in one direction.
The return movement is caused by a spring. Cylinders of this type are called "single-
action cylinders".

29
 Fig: 4.7 Working of pneumatic cylinder (Forward stroke)
To move the cylinder outwards, valve V1 must be open (the coil is supplied
with electric current) and valve V2 closed (Fig: 4.7) (no current flowing).

Fig: 4.8 Working of pneumatic cylinder (Reverse stroke)

To move the cylinder inwards, valve V2 is open and valve V1 closed (Fig:
4.8). The diagram also makes it clear why vent "R" on the valve is required. Without
this vent, the cylinder would be unable to move as the same pressure would be

30
exerted on both sides of the piston and the air would not be able to escape. The
pneumatic system uses manually or electrically operated valves to control direction
of movement. Directional control valves can be operated by hand lever or electric
solenoid to maintain an adjustable travel rate. The internal porting or spool of the
directional control valve regulates airflow.
The exhausting air passes through the flow control valve and the directional
control valve located at the end of the cylinder and exhausts to the atmosphere.
When the cylinder retracts, the flow control valve at the end of the cylinder controls
the flow, and the first valve allows air freely through. The 3D model of pneumatic
cylinder is as shown (Fig: 4.9)

Fig: 4.9 3D modeling of pneumatic cylinder

Because pneumatic systems always contain moisture from the air, the system
should not be allowed to freeze. Freezing can damage the seals and control surfaces,
allowing air leakage past valves, or locking a valve from operating.
Check valves may be inserted in the line to be sure the cylinder will stay in the
desired position and not drift. This is useful in case some part is leaking, or there is a
loss of air pressure in the plant system.
4.7. SOLENOID VALVE
A solenoid valve is an electromechanical valve for use with liquid or gas
controlled by running or stopping an electrical current through a solenoid, which is a
coil of wire, thus changing the state of the valve. The operation of a solenoid valve is
similar to that of a light switch, but typically controls the flow of air or water,
31
whereas a light switch typically controls the flow of electricity. Solenoid valves may
have two or more ports: in the case of a two-port valve the flow is switched on or
off; in the case of a three-port valve, the outflow is switched between the two outlet
ports. Multiple solenoid valves can be placed together on a manifold. Solenoid
valves are the most frequently used control elements in fluidics. Solenoids offer fast
and safe switching, high reliability, long service life, good medium compatibility of
the materials used, low control power and compact design.
Solenoid valves may use metal seals or rubber seals, and may also have electrical
interfaces to allow for easy control (Fig: 4.10).

Fig: 4.10 Working of Solenoid valve

A-Input side; B- Diaphragm; C- Pressure chamber; D- Pressure relief conduit;

E- Solenoid; F- Output side.
The diagram to the right shows the design of a basic valve. If we look at the
top figure we can see the valve in its closed state. The water under pressure enters at
A. B is an elastic diaphragm and above it is a weak spring pushing it down. The

32
function of this spring is irrelevant for now as the valve would stay closed even
without it. The diaphragm has a pinhole through its center which allows a very small
amount of water to flow through it. This water fills the cavity C on the other side of
the diaphragm so that pressure is equal on both sides of the diaphragm. While the
pressure is the same on both sides of the diaphragm, the force is greater on the upper
side which forces the valve shut against the incoming pressure. Now let us turn our
attention to the small conduit D. Until now it was blocked by a pin which is the
armature of the solenoid E and which is pushed down by a spring. If we now
activate the solenoid, the water in chamber C will flow through this conduit D to the
output side of the valve. The pressure in chamber C will drop and the incoming
pressure will lift the diaphragm thus opening the main valve. Water now flows
directly from A to F. The 3D model of solenoid valve is as shown (Fig: 4.11).

Fig: 4.11 3D-modeling of solenoid valve

4.8. CONTROL UNIT:

Microcontrollers are destined to play an increasingly important role in

revolutionizing various industries and influencing our day to day life more strongly
than one can imagine. Since its emergence in the early 1980's the microcontroller
has been recognized as a general purpose building block for intelligent digital

33
systems. It is finding using diverse area, starting from simple children's toys to
highly complex spacecraft. Because of its versatility and many advantages, the
application domain has spread in all conceivable directions, making it ubiquitous. As
a consequence, it has generate a great deal of interest and enthusiasm among
students, teachers and practicing engineers, creating an acute education need for
imparting the knowledge of microcontroller based system design and development.
It identifies the vital features responsible for their tremendous impact, the acute
educational need created by them and provides a glimpse of the major application
area.

A microcontroller is a complete microprocessor system built on a single IC.

Microcontrollers were developed to meet a need for microprocessors to be put into
low cost products. Building a complete microprocessor system on a single chip
substantially reduces the cost of building simple products, which use the
microprocessor's power to implement their function, because the microprocessor is a
natural way to implement many products. This means the idea of using a
microprocessor for low cost products comes up often. But the typical 8-bit
microprocessor based system, such as one using a Z80 and 8085 is expensive. Both
8085 and Z80 system need some additional circuits to make a microprocessor
system. Each part carries costs of money. Even though a product design requires
only very simple system, the parts needed to make this system as a low cost product.

34
 CHAPTER-5

DESIGN CALCULATION

5.1 FRAME

The square pipe frame is used to carry the entire system of child rescue system
5.1.1 VERTICAL SUPPORT

Consider the material is mild steel square pipe of dimension,

19.05×19.05×1 mm
600 mm

600 mm

19.05mm

35
Consider the maximum load by child =100N and hence each support should
withstand 25 N

Young’s modulus, E = σb/e Where,

σb = Bending stress
e = ΔL/L and ΔL= PL/AE
e = strain =ΔL/L
= 25×600/37.1×2×105
ΔL = 0.00202 mm
Therefore, e = 0.00202/600
e = 3.369×10-6

E = σb/e
2×105 = σb /3.369×10-6
σb = 0.674 N/mm2
Maximum Bending stress for mild steel , σb max = 248 N/mm2
Hence, σb < σb max
Design is safe

5.1.2 HORIZONDAL SUPPORT

Consider the load acting on horizondal support as simply supported

beam

100 N

600 mm
50 N 50 N

36
 Bending Moment, Mb =300 mm ×50 N
= 15000 N-mm
We know that. Bending stress, σb = Mby/I Where,
Mb = Bending moment
y = Deflection
3
I=bd /12 I = Inertia

For hollow pipe, I = (bd3 – b1d13)/12

= {(19.05×19.053)-(18.05×18.053)}/12

I = 2129.25 mm4

Deflection, y = ΔL= PL/AE

= 100×600/37.1×2×105
= 0.00809 mm

Bending stress, σb = Mby/I

= 15000×0.00809 /2129.25

σb = 0.0057 N/mm2
Maximum Bending stress for mild steel , σb max = 248 N/mm2
Hence, σb < σb max
Design is safe
5.2 PNEUMATIC CYLINDER

Mini pressure applied in the cylinder (P) = 2x105N/m2 (2 bar)

Diameter of the cylinder (D) = 16 mm

Diameter of the piston rod (d) = 12 mm

Stroke length = 50 mm

37
Area of cylinder (A) = (3.14/4x(D2)

= (0.785x0.0162)

A= 2.011 x 10-4 m2

Force during forward stroke,

F = {π/4x D^2 x P}

F = (2 x 105 N /m2) (3.14 / 4 x (0.0162)

F = 40.21 N

1kg = 9.81 N

Load capacity during forward stroke W= F / a

W = 40.21 / 9.81

W= 4.1 kg

Force during return stroke,

F = {π/4x (D^2 – d^2) x P}

F = {π/4x (0.032^2 – 0.006^2) x 2x105}

F = 34.555 N

Load capacity during return stroke W= F / a

W= 115.45 / 9.81

W= 3.52 kg

For all practical purposes, design your system 25% over and above your

theoretical calculations.

38
 Fig: 5.1 Graph for distingution between Force Vs Air pressure

5.2.1 THEORETICAL AIR CONSUMPTION CALCULATIONS:

During Forward stroke,

Air consumption = {π/4x (D^2) x L}

Air consumption = {π/4x (0.016^2) x 0.05}

Air consumption = 1.005 x 10-5 m3

1 m3 = 1000 liter

Air consumption = 0.01005 liter

39
Boyles Law, P1V1 = P2V2

V2 = P1V1/ P2

V2 = (2+1) (0.01005)/ 1

V2 =0.03015 liter /stroke

During return stroke,

Air consumption = {π/4x (D^2- d^2) x L}

Air consumption = {π/4x (0.016^2 – 0.006^2) x0.0.05}

Air consumption = 8.64 x 10-6 m3 = 0.00864 liter

Boyles Law, P1V1 = P2V2

V2 = P1V1/ P2

V2 = (2+1) (0.00864)/ 1

V2 = 0.02592 liter /stroke

Theoretical air consumption per cycle = (Air consumption during

forward stroke + Air consumption during return stroke)

Theoretical Air consumption per cycle =0.01005 + 0.00864

= 0.01869 liter/ cycle

40
In actual practice, approximately 2/3 of this flow is obtained. Assume 75% of

line pressure (PSI) is actually working on the load. The remaining 25% is

consumed by flow losses in the valve and connecting lines.

5.2.2 SELECTION OF STANDARD PNEUMATIC CYLINDER

DESIGN PARAMETER

Required load to be lifted = 5 kg

Factor of safety for pneumatic cylinder = 3 (Constant Load)

Supply Pressure = 2 bar

Load to be lifted = 4 kg =4 Kg x 9.81 m/s2 = 39.24 N

Design load = Load to be lifted x Factor of safety

Design load = 39.24 x 1 = 39.24 N

{ D^2 } = F/( π/4 x P)

{D^2 } = 39.24 /( π/4 x 2 x 105)

D = 0.0158 m= 15.8 mm

41
 Table: 5.1 Standard pneumatic cylinder size

DIAMETER STROKE LENTH

100 100
125 100
15 100
16 100
16 50
20 150
32 100
32 150
32 25
32 300
32 750
40 100
50 100

From table,
16 diameter cylinder is enough for particular design load and length of
piston rod depends upon the application.

5.3 ROPE

TO FIND ROPE TENSION

Tension, T = mg + ma (a= 5 m/s2 ; m=10 kg)

= (10 x 9.81) + (10 x 5)
T =150N
T = mg +ma (a= 0 m/s2 ; m=10 kg)
= 10 x 9.81
= 100 N

T = mg +ma (a= -5 m/s2 ; m=10 kg)

42
 = (100-50)
T = 50 N
T=150 N is the maximum Tension
Area of cross section of rope = F/{( σv /n)-(dw / Dmin x E)}
= 150/{(420/35)-(1/100x0.8x104)}
= 140/40
= 3.75 mm From PSG design data
book
Area of cross section of rope= 0.4x3.14xD2
σv = 420 N/mm2
3.75 = 0.4x3.14xD2 D/d= 100
n = 3.5
D =3.5 mm

Design stress on Rope, σd = (W+Wr)/A

= 100 / (3.14/4x3.52x0.4)
σd =26 N/mm2
Maximum Design stress for wire rope , σd max = 320 N/mm2
Hence, σd< σd max
Design is safe

5.4 WORM AND WORM GEAR

Number of teeth on worm wheel = 24

Outer diameter of worm wheel = 53 mm

Inner diameter of worm wheel = 10 mm

Number of starts on worm = 8

43
 Motor speed = N = 30 rpm

Power of motor = P = 0.0048 HP

Diameter of shaft = 10 mm

Mild steel shaft shear stress = fs = 210 N / mm^2

Torque of the motor = T = p x 60 / 2 x π x N

= 3.58 x 60 / 2 x π x 30

= 1.14 N-m

Gear ratio (i) = n1 / n2

(N2 = N1 / Gear ratio)

(n1) worm shaft speed = 1500 rpm

= 30/ 24

(n2) worm wheel speed = 1.25 rpm

Torque of the worm wheel (t2) = p x 60 / 2 x π x N2

= 3.58 x 60 /2 x π x 1.25

= 27.35 N m

Angular velocity of worm wheel = 2 x π x 1.25 / 60

= 0.13 rad

Maximum torque rate of the worm wheel = π/16 x fs x d3

= π/16 x 210 x 103

= 41233.4 N m

44
Worm wheel torque is limited to the maximum limit. So our design is safe.

Hence the worm wheel used here rotates at = 1.25 rpm

45
 CHAPTER-6

DESIGN AND MODELING

6.1 2D-DESIGN

Fig: 6.1 2D Design of child rescue system using AutoCAD 2007 software
6.2 3D-PART MODELING

6.2.1 FRAME

46
 Fig: 6.2 3D Modeling of Frame

6.2.2 CLAMP SET-UP

Fig: 6.3 3D Modeling Clamp set-up

6.2.3 PNEUMATIC CYLINDER SET-UP

Fig: 6.4 3D Modeling of pneumatic cylinder set-up

47
6.2.4 WORM AND WORM GEAR

Fig: 6.5 3D Modeling of Worm gear set-up

6.3 3D-ASSEMBLY MODELING

Fig: 6.6 Assembled Model

In our project, the parts were modeled by using CREO 3.0 software.

48
 CHAPTER-7

FABRICATION PROCESSES

7.1 MANUFACTURING PROCESSES

Manufacturing processes transforms raw materials into a final product. The

manufacturing process begins with the creation of the materials and the design of
material. These materials are then modified through manufacturing processes to
become the required part. Manufacturing processes can include treating, machining
using lathe (Fig: 7.1), or reshaping the material.

7.1.1 LATHE OPERATIONS

Fig : 7.1 Lathe Machine

In machining, facing is a process to reduce the length of the work piece

by using single point cutting tool. It is the act of cutting a face, which is
a planar surface, onto the work piece. Facing in the course of milling work (for

49
example, face milling). Other types of machining also cut faces (for
example, planning, shaping, and grinding) (Fig: 7.2).

Fig: 7.2 Lathe Operations

Turning is a machining process in which, the diameter of the work piece

is reduced by the cutting tool, typically a non-rotary tool bit, describes
a helix tool path by moving more or less linearly while the work piece rotates.
Those types of turning processes can produce various shapes of materials such
as straight, conical, curved, or grooved work piece. In general, turning uses
simple single-point cutting tools.

7.1.2 DRILLNG

Drilling is a cutting process that uses a drill bit to cut or enlarge a hole of
circular cross-section in solid materials (Fig: 7.3). The drill bit is a rotary
cutting tool, often multipoint. The bit is pressed against the workpiece and
rotated at rates from hundreds to thousands of revolutions per minute. This

50
forces the cutting edge against the workpiece, cutting off chips (swarf) from the
hole as it is drilled.

The geometry of the common twist drill tool (called drill bit) is complex.
It has straight cutting teeth at the bottom these teeth do most of the metal
cutting, and it has curved cutting teeth along its cylindrical surface.

Fig: 7.3 Drilling Machine

Drilling is not useful for very small diameter holes (e.g. < 0.5 mm), the
tool may break and get stuck in the work piece, the size of the hole made by a
drill is slightly larger than the measured diameter of the drill, this is mainly
because of vibration of the tool spindle as it rotates, possible misalignment of
the drill with the spindle axis, and some other factors.

51
 Fig: 7.4 Drilling Operation

Tight dimension control on hole diameter by drill a hole that is slightly

smaller than required size (e.g. 0.25 mm smaller), and then use a special type
of drill called a reamer. Reaming has very low material removal rate, low depth
of cut, but gives good dimension accuracy (Fig: 7.4).

7.1.3 METAL CUTTING

Metal cutting or machining is the process of by removing unwanted material

from a block of metal in the form of chips. Cutting processes work by causing
fracture of the material that is processed. The portion that is fractured away is in
small sized pieces, called chips. Common cutting processes include sawing, shaping
(or planning), broaching, drilling, grinding (Fig: 7.5), turning and milling.

52
 Fig: 7.5 Portable Metal cutting
The actual machines, tools and processes for cutting look very different from
each other, the basic mechanism for causing the fracture can be understood by just a
simple model called for orthogonal cutting (Fig: 7.6).

Fig: 7.6 Metal Cutting Machine

53
7.2 ASSEMBLY

7.2.1 WELDING:

Welding is a process for joining similar metals. Welding joins metals by

melting and fusing 1, the base metals being joined and 2, the filler metal applied
(Fig: 7.7). Welding employs pinpointed, localized heat input. Most welding
involves ferrous-based metals such as steel and stainless steel. Weld joints are
usually stronger than or as strong as the base metals being joined.

Fig: 7.7 Weld

Welding is used for making permanent joints. It is used in the manufacture

of automobile bodies, aircraft frames, railway wagons, machine frames,
structural works, tanks, furniture, boilers, general repair work and ship building.
The operator needs to control the gap between the electrode tip and the
work piece, the electrode moving along the joint (Fig: 7.8).

54
 Fig: 7.8 Welding Process

In the shielded metal arc welding process (SMAW) the 'stick' electrode is
covered with an extruded coating of flux. The heat of the arc melts the flux
which generates a gaseous shield to keep air away from the molten pool and
also flux ingredients react with unwanted impurities such as surface oxides,
creating a slag which floats to the surface of the weld pool. This forms a crust
and it protects the weld while it is cooling. When the weld is cold the slag is
chipped off.

7.2.2 SOLDERING
Soldering is a process in which two or more items (usually metal) are
joined together by melting and putting a filler metal (solder) into the joint, the
filler metal having a lower melting point than the adjoining metal. Soldering
differs from welding in that soldering does not involve melting the work
pieces. In brazing, the filler metal melts at a higher temperature, but the work
piece metal does not melt. In the past, nearly all solders contained lead, but

55
environmental and health concerns have increasingly dictated use of lead-free
alloys for electronics and plumbing purposes.
Soldering filler materials are available in many different alloys for
differing applications. In electronics assembly, the eutectic alloy of 63% tin and
37% lead (or 60/40, which is almost identical in melting point) has been the
alloy of choice. Other alloys are used for plumbing, mechanical assembly, and
other applications. Some examples of soft-solder are tin-lead for general
purposes, tin-zinc for joining aluminium, lead-silver for strength at higher than
room temperature, cadmium-silver for strength at high temperatures, zinc-
aluminium for aluminium and corrosion resistance, and tin-silver and tin-
bismuth for electronics (Fig: 7.9 & 7.10).

Fig: 7.9 Soldering

56
 .
Fig: 7.10 Soldering process

57
 CHAPTER-8

WORKING PROCEDURE

Fix the frame on a bore well and adjust it to coincide the axis of borewell and
axis of rope. Rotate the handle to move down the whole set up into a bore well
through rope
Connect the camera with PC and rotate the camera using DC motor to identify
the position of child. When the child’s image is found in PC, analyze the position of
child and its movement, lock the pneumatic cylinders 1, 2 an 3 using Solenoid valve
1 to avoid oscillation of rope. Identify the clamp position which moves in between
the child and inner surface of the borewell
Lock the child by actuating the motion of movable clamp with respect to the
movement of piston of pneumatic cylinder 4.
If the clamp holds the child in proper position, Release the above pneumatic
cylinders and lift the child through rope. Otherwise try again until the clamp holds
the child in proper position.

58
 CHAPTER-9

RESULT AND DISCUSSION

The system we constructed to rescue the child is easier to operate than the
existing methods of child rescue systems. The time taken for rescue the child is very
less in this system. The safety of the child inside the borewell is considered as a
major factor to construct this system. The design of this system is modified with
high factor of safety. But this system requires air compressor to actuate the
pneumatic cylinders that locks the child safely. This project is made with pre
planning, that it provides flexibility in operation. Smoother and noiseless operation.
In this rescuing operation time is a vital factor which alone can deter mine the
success or failure of the whole operation. Thus it has been designed keeping the
entire obstacle in mind that may arise during the operation.

COMPARISON WITH EXISTING METHODS

While comparing with the existing methods of child rescue system, it is
much better than the traditional method. The child rescue robots may cause injury to
the child. But, this system is designed to avoid these drawbacks from the existing
system. The time taken to rescue the child from borewell is much less then the
existing system. It is easy to operate the pneumatic cylinder using the solenoid
valves.

59
 CHAPTER-10

COST OF ESTIMATION

The cost estimation for child rescue pneumatic system is shown in the Table
10.1

Table: 10.1 Cost Estimation

S.NO COMPONENT QUANTITY COST(₨)

Pneumatic cylinder
1 4 6000
Solenoid valve
2 2 1700
Circular plate
3 2 80

4 MS rod 1 50
Camera
5 1 500
Dc motor
6 1 220
Worm and worm gear
7 1 140
Relays and circuit board
8 2 300
Square pipe, Wires, pipe
9 and tubes As required 5800

Total cost 14,790

CHAPTER-11

60
 WORKING MODEL OF CHILD RESCUE SYSTEM

11.1 PHOTOGRAPHS

Fig: 11.1 Assembled view 1 Fig: 11.2 Assembled view 2

CHAPTER-12

61
 CONCLUSION

This project is made with pre planning, that it provides flexibility in operation.
Smoother and noiseless operation by the medium of “child rescue pneumatic
system”. The comparative gain that can be accomplished is the utilization of roller
bar. This innovation has made the more desirable.
This project is designed with the hope that it is very much economical and help full
to many industries, workshops and to rescue the child from borewell accidents. This
project helped us to know the periodic steps in completing a project work. Thus we
have completed the project successfully.

REFERENCES

62
1. G. Kavianand, K. G. Ganesh and P. Karthikeyan (2014) ‘Smart child rescue
system from borewell (SCRS)’, International Conference on Robotics and
Automation for Humanitarian Applications.,Vol.4, pp.2465-3350.
2. Nish Mohith Kurukuti (2014) ‘A novel design of robotic system for rescue in bore
well accidents’, 2016 International Conference on Emerging Trends in Engineering,
Technology and Science (ICETETS), Vol.4, pp.2254-8655.
3. Manish Raj (2015) ‘Design of a child rescue robot using a pneumatic arm
system’, Vol.20, pp. 626-723.
4. Albert Francis A (2011) ‘Design Ground Bio‐inspired Micro‐Robot Structure for
Detecting Humans in disastrous region Wright State University’, Vol.1, pp. 8-10.
5. N. Bourbakis and I. Papsadakis‐Ktistakis (2013) ‘Battery Management system for
Rescue Robot’, Vol.6, pp. 2654-8945.
6. K. P. Sridhar C. R. Hema S. Deepa ‘Rescue Child from wireless sensor fusion
System, International journal of innovative research in science’,Vol.5, pp. 1-10
7. Navya Amin Singh and Markus Borschbach (2014) ‘Design And Simulation Of
Bore Well Rescue Robot’, Vol.9, pp. 256-258.
8. Preedipat Sattayasoonthorn and Jackrit Suthakorn (2016),’An Approach to Design
of Child Saver Machine for Child Trapped in Borehole with battery management’,
Vol.1, pp.26-38.
9. Shuhai Wang, “Rescue System for Borewell Accidents using ultrasonic sensor’,
Vol.3, pp. 2230-3250.
10. Wang Chuanjiang (2012) ‘Borewell rescue robot for caliber wells using
hardware system’, Vol.2, pp. 2276-3138.

63