Design And Manufacturing Of Truck Tubeless Tyre Changer Machine

1. INTRODUCTION

The traditional tire changing process by using manually operated tire changer
may involve high force to remove tire from heavy wheels .The process of removing
tire from heavy wheels involves bending, hard pressing and twisting. This can cause
injuries to shoulder, wrist and knees, lower back. Injuries can occur suddenly over
time. Some other major factors that are taken into consideration while doing this
machine are as follows:
1. Cost of power operated ‘tire removing machine’ is much higher as compared to
traditional manual tire removing and fitting process.
2. Removing or fitting of tire on rim of wheel by conventional manual technique is
very effortful and time consuming process.
3. Sometimes, hand tool, which is used for removing the tire from rim of wheel will
damage the tube and tire of wheel due to it is not properly handle, or due to human
handling error.
4. For conventional skilled and experienced operator is required.
5. Pneumatic method uses air pressure for dismantling or separating the tire from the
disc .

This method is very quick and effective but the only limitation for this method is
that it is very costly so small scale service center of owners cannot afford this.
Manually operated tire pressing machine that we have fabricated is the efficient way
for removing the heavy tire from the wheels. In this project we are going to combine
the advantages of both conventional as well as pneumatic methods. This machine is
quick in operation like the pneumatic method but also very economical as the
conventional method.
Manually operated tire pressing machine [motpm] reduces most of the cost
required in the pneumatic method and reduces the effort of the worker considerably.+

This machine is use for tire removing and fitting on Rim of wheel. In this machine
wheel is clamped on the mounting base. The wheel rim is tightly fixed on the

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mounting wheel. This tire removing and fitting machine used to help tire technicians
dismount and mount tires of automobile wheels. After the wheel and tire assembly are
removed from the automobile, the tire changer has all the components necessary to
remove and replace the tire from the wheel. This machine allow technicians to replace
tires on automobiles, motorcycles and heavy-duty.

1.1.Problem Statement

Removing or fitting of tire on rim of wheel by conventional manual technique is very

effortful and time consuming process. This is an invension that took place in recent
year to eliminate human factor from the work which is a risky task. Cost of power
operated ‘tire removing machine’ is much higher as compared to semi automatic truck
tubeless tyre changer machine.

1.2.Objective

The main objective of our machine are as below:

 To reduce human efforts

 To reduce cost of machine

 To reduce operational time.

1.3.Methodology

This aims to design and Manufacturing of semi automatic tyre changer machine for
reducing human efforts of removing the tire from heavy vehicles. For Manufacturing
of Semi automatic tyre changer machine the tyre dimensions and force required has
been determined .Then design and cad model has been prepared in software. computed
result of analytical calculations, design modification by reference of analytical value

which has compared with design calculations.

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1.4 Applications
Time is a very important aspect of life, and as engineers we always seek to come up
with
easy and efficient solutions for problems. Therefore, mainly, our project focuses on the
aspect of reducing the amount of time taken in changing tires and the effort required to
change the tyre . This project can be used in
a variety of places, such as workshops and tire manufacturing companies. On one
hand, there are many manufacturing
companies, and workshops that use impact wrenches as a tool for changing tires, and
they
have to required lots of human efforts and time to operation. On
the other hand, our project can efficiently save time by

2.LITERATURE REVIEW

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R.D.Rajopadhye1, Vartak Chinmay P2, Dalvi Mahesh R3, Rahate Tejas G4,
Nazare Sanket [1]”Design and fabrication of manually operated tyre pressing
machine for reducing human efforts in removing tyres of heavy vehicles”
In present scenario in case of tyre worn out or air leakage in tyre of heavy vehicles
like tractors, transport vehicles. The conventional method used to remove the tyre
consumes a lot of efforts of the labour.the conventional method uses the different
source of energy like mechanical and pneumatic. By using conventional method which
involves hammers and rods for removing the tyre from heavy wheels leads to the
chances of serious injuries .This paper deals with design and fabrication of manually
operated tyre pressing machine for reducing human efforts in removing tyres of heavy
vehicles .
The newly developed method combines the advantages of both conventional as well as
pneumatic method and also it is time and cost effective.

Pornima T. Godbole1 C. C. Handa2 S. P. Bhorkar3[2] “ Machine for Tire

Removing and Fitting on Rim of Wheel” In the present context of market situation,
there is always a need for better design of the equipment with the maximum reduction
in cost. Added to these is the human comfort which enables a person to operate it with
ease and least consumption of human effort. The 'tire-changer' equipment is used by
vulcanizing shops, retailers of tires, tire retreading works and servicing stations for
easy tire demounting and mounting operations from or on to the wheel disc or rim of
light motor vehicles. With these 'tire-changer' machines, no extra manpower is
required as only one person can do the entire job in less time. The main objective
provide information of existing tire changer equipments and fabricate low cost manual
'tire-changer' equipment to develop self-employment opportunities. In this paper some
existing machine related to tire changer machine is discussed.

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Mr. Sutar Gururaj1,Mr. Suryawanshi Bhairavnath 2, Mr. Tengle Kiran3 Mr.

Thaware Madan[3] “Study And Analysis Of Tire Changing Machine
Components” t-Now a days in automobile field new features and new generation are
rapidly increases, due to this regularly do maintenance of vehicle is main role of user.
So our study is focus on the safety of operator in service centre. In service centre
mostly used machine is tire changing machine for removing and mounting of tire from
rim. Safety and less effort of operator is important when operating this machine. Also
study the gearbox design of Tire changing machine.

Development of
A. J. Abegunde P. O. Ajewole [4] “

Anelectrically Operated Tyre

Removing Machine” Removal of vehicle tyres has being so strenuous for
road side vulcanizers in Nigeria due to the manual labour
exerted during the process. In reducing the labour
requirement as described by ergonomist Phelani in his
book,[7], an electrically operated tyre removing machine was
developed. The objective of the project is to make the process
of tyre removal from vehicles for repair purpose easier than
the local method commonly used. The machine comprises of
the actuator, plunger blade, tyre seat, switch control and
frame supports. The elements of the machine were assembled
and coupled together using both fastening and welding
method. [2] It was found that the efficiency of the machine
was very high and it removes tyres with ease.

3.WORKING PRINCIPLE

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This aims to design and Manufacturing of semi automatic tyre changer machine for
reducing human efforts of removing the tyre from heavy vehicles and reduce the cost
of Machine

3.1..AUTOMATIC TYRE CHANGER MACHINE

3.1.Block Diagram

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3.1.1 Front View Of Experimental Setup

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3.1.2 Side View Of Experimental Setup

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Chapter 4
Concept
4.1 Construction and working
Demounting procedure
• Release all the air inside the tire.
• Place the tire between the bead breaker shoe and rubber pad to
separate the bead from the rim.
• Clamp the rim on the turntable
• Lubricate the bead with soap solution.
• And turn the turntable clockwise to let the bead separate from the
bead seat using tool.
Hence the tubless tyre can be easily demontedv
Mounting procedure
• Clamp the rim on the turntable
• Lubricate the bead with soap solution.
• Place the tyre on the rim
• And turn the turntable clockwise to let the bead Enter the bead seat
using tool.
• Hence the tubless tyre can be easily monted.
• Fill the air inside the tyre.
4.2 Software required
Catia v5r20
4.3Hardware required
 Electric Motor
 Motor Gearbox
 Pulleys
 Turning Plate
 Gearbox

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 Base
 Tool
 Extending arm
 Control unit
 Counter Shaft
 Belt

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Chapter 5
component
5.1.Electric Motor

An electric motor is an electrical machine that converts electrical

energy into mechanical energy. Most electric motors operate through the interaction
between the motor's magnetic field and winding currents to generate force in the form
of rotation. Electric motors can be powered by direct current (DC) sources, such as
from batteries, motor vehicles or rectifiers, or by alternating current (AC) sources,
such as a power grid, inverters or electrical generators. An electric generator is
mechanically identical to an electric motor, but operates in the reverse direction,
accepting mechanical energy (such as from flowing water) and converting this
mechanical energy into electrical energy.

Electric motors may be classified by considerations such as power source type,

internal construction, application and type of motion output. In addition to AC versus
DC types, motors may be brushed or brushless, may be of various phase (see single-
phase, two-phase, or three-phase), and may be either air-cooled or liquid-cooled.
General-purpose motors with standard dimensions and characteristics provide
convenient mechanical power for industrial use.

5.1.Electric motor

5.1.1 parameters for motor selection

 The power required to run the empty machine.

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 The power required to rotate the turn plate of machine.

5.1.2 specification of motor:
 1440 rpm 12V AC motors with speed reduction gearbox.
 7cm shaft diameter with internal hole.
 1.5 HP three phase motor.
 Company: BHARAT BIJLIEE.

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5.2Pulley

A pulley is a wheel on an axle or shaft that is designed to support movement and

change of direction of a taut cable or belt, or transfer of power between the shaft and
cable or belt. In the case of a pulley supported by a frame or shell that does not transfer
power to a shaft, but is used to guide the cable or exert a force, the supporting shell is
called a block, and the pulley may be called a sheave.

A pulley may have a groove or grooves between flanges around its circumference to
locate the cable or belt. The drive element of a pulley system can be a rope, cable, belt,
or chain.

5.2Pulley

5.3Gear Box

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A transmission is a machine in a power transmission system, which provides

controlled application of the power. Often the term transmission refers simply to
the gearbox that uses gears and gear trains to provide speed and torque conversions
from a rotating power source to another device.
In British English, the term transmission refers to the whole drivetrain,
including clutch, gearbox, prop shaft (for rear-wheel drive), differential, and final
drive shafts. In American English, however, the term refers more specifically to the
gearbox alone, and detailed usage differs
The most common use is in motor vehicles, where the transmission adapts the output
of the internal combustion engine to the drive wheels. Such engines need to operate at
a relatively high rotational speed, which is inappropriate for starting, stopping, and
slower travel. The transmission reduces the higher engine speed to the slower wheel
speed, increasing torque in the process. Transmissions are also used on pedal bicycles,
fixed machines, and where different rotational speeds and torques are adapted.
Often, a transmission has multiple gear ratios (or simply "gears") with the ability to
switch between them as speed varies. This switching may be done manually (by the
operator) or automatically. Directional (forward and reverse) control may also be
provided. Single-ratio transmissions also exist, which simply change the speed and
torque (and sometimes direction) of motor output.

5.4 Gear box

5.5Actuator

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An actuator is a component of a machine that is responsible for moving and

controlling a mechanism or system, for example by opening a (valve). In simple terms,
it is a "mover".

An actuator requires a control signal and a source of energy. The control signal is
relatively low energy and may be electric voltage or current, pneumatic or hydraulic
pressure, or even human power. Its main energy source may be an electric
current, hydraulic fluid pressure, or pneumatic pressure. When it receives a control
signal, an actuator responds by converting the signal's energy into mechanical motion.

An actuator is the mechanism by which a control system acts upon an environment.

The control system can be simple (a fixed mechanical or electronic system), software-
based (e.g. a printer driver, robot control system), a human, or any other input.

5.5 Actuator

5.6.Base Bed

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The function of support bed to support the whole structure. It is made of mild steel. It
is easily available in the market In the form of c-beam or d-beam.

5.6Bed
5.7 Belt

belt is a loop of flexible material used to link two or more rotating shafts mechanically,
most often parallel. Belts may be used as a source of motion, to transmit
power efficiently or to track relative movement. Belts are looped over pulleys and may
have a twist between the pulleys, and the shafts need not be parallel.

In a two pulley system, the belt can either drive the pulleys normally in one direction
(the same if on parallel shafts), or the belt may be crossed, so that the direction of the
driven shaft is reversed (the opposite direction to the driver if on parallel shafts). As a
source of motion, a conveyor belt is one application where the belt is adapted to carry
a load continuously between two points.

5.6 v Belt

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3. DESIGN OF GEAR BOX

The main purpose of a gearbox is to transmit power required or demand to variable needs from an
input power source to the desired output machine. A Gearbox is a mechanical device that is used
to provide desirable different Speed and Torque transfer to output gearbox shaft to machine input
shaft. As the speed of the shaft increases, the torque transmitted decreases because speed require
frequent changes to the speed or torque at the output shaft. Gearboxes work on the principle of
meshing of teeth, which result in the transmission of motion and power from the input source to
the output.
Some of the primary components used in a Gearbox are listed below.
1. Gears
2. Bearings
3. Shafts

3.1 Calculations
Initial Specifications for the Gearbox
Given data -
Motor speed = 1440 rpm
1. Gear box output speed = 144rpm
2. Input power – 1.1kw
3. Geometric progression ratio (Ø) =5√10 = 1.5848 - (automatic or semi automatic machine)
4. Range ratio (Rn) =Nmax/Nmin = =144
5. Speed steps (Z) =?

Ø= Rn( 1/z-1)

Z= log (Rn+ Ø)/ log Ø

Z = 5.325= 6

Calculate speed steps (spindle speeds)

Speed steps Spindle speed (rpm) Output Speed
Equations
1 Nmin =144 144
2 N2=Ø× N1=228 228
3 N3=Ø×N2=361.66 361.66
4 N4=Ø×N3=573.17 573.17
5 N5=Ø×N4=908.35 908.35
6 N6= Ø×N5=1440 1440

6.ADVANTAGES

• Low Cost of machine as compared with Automatic Machine.

• Construction is simple as compared to Automatic Machine.
• Long Life due to High Strength of Structure.
• It Reduces Human Effort of Operator.
• Machine Parts are Easily Available at Market.

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7.DISADVANTAGES

• High Skilled Operator is Required.

• Its Takes More Time Than Automatic Machine.
• It is Only Useful For Tubeless Tyre.

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• Heavy Construction.

8.CONCLUSION

we will collect required data and will design and modifies tire removing and fitting
machine. The approach will be synthesis, design, development & testing of the
machine. The various parameters such as design of tool, design mounting base will be
carried out to make the machine.

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Methodology is a systematic theoretical analysis of the body of methods and principles

associated with a branch of knowledge typically it encompasses concepts such as,
theoretical model , phases and quantitative and qualitative techniques.
The above references can be used by designer interested in design of tire changer.

9.FUTURE SCOPE
Today, the most significant innovations are targeted around low-rolling resistance of
tyres. It's the energy efficiency of our tyres. This is pulled by environmental desires to
consume less fuel as is regulated by many countries around the world with higher

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expectation for lower fuel consumption. Because the less fuel you consume, it is better
for the environment.
Tyres play an important role in energy consumed by the vehicle. In passenger cars
around 20 per cent of the energy consumed by the vehicle is just to make the tyres roll.
Tyres consume a lot of energy because they flex when heat builds-up.
On trucks and buses, it's even more significant; tyres consume 30-35 per cent of fuel in
these vehicles.

10.REFERANCES

[1] Demounting And Mounting Procedures For Tube--Type Truck And Bus Tiires
Manuals By Osha Occupational Safety And Health Administration

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[2] Tom Duke Contributing Editor Tire Mounting And Demaunting Tire Review In
May 2012
[3] Michelin Truck Tire Data Book Mounting Safety Instructions. United States
Michelin North America
[4] Installation And Operational Manual Model:R745 Tire Changer Bendpak Inc. /
Ranger Products 1645 Lemonwood Dr. Santa Paula, Ca. 93060
[5] Radial Truck Tire And Retread Service Manual Goodyear Printed In Usa
[6] M. Guiggiani, The Science Of Vehicle Dynamics Mechanics Of The Wheel With
Tire
[7] Nicholas D. Smith Colorado State University, 2004 Formula SAE Platform
Understanding Parameters Influencing Tire Modeling
[8] A Textbook of Machine Design by R. S. Khurmi & J. K. Gupta.ISBN:978-81-219-
2537-2 (pp 53-86, 3431-469, 624- 676)
[9] A Textbook of Design of Machine Element by V.B. Bhandari,ISBN-13 :978-07-
068179-8 (pp 1-53, 184-194)
[10] Demounting and Mounting Procedures For Tube-Type Truck And Bus Tires
Manuals By Osha Occupational Safety And Health Administration
[11] Tom Duke Contributing Editor Tire Mounting And Demaunting Tire Review In
May 2012
[12] ATLAS TC-733 Automatic Car Tire Changer Maintenance Manual
[13] Pornima T. Godbole, C. C. Handa , S. P. Bhorkar “ Machines For Tire Removing
And Fitting On Rim Of Wheel.” IJSRD - International Journal for Scientific Research
& Development Vol. 4, Issue 05, 2016
[14] Hai-Jun Su,Deis V.Dorozhkin And Judy M.Vance , “Screw Theory Approach For
The Conceptual Design Of Flexible Joint For Compliant Mechanisms” Journal Of
Mechanisms And Robotics Vol. 1,Issue 04,2009

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