Emergency Braking System
Emergency Braking System
Emergency Braking System
INTRODUCTION
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Development and assessment of an electro-hydraulic-
Individual wheel braking combined with traction control
Assessing sensor failure and fault tolerant control systemdesign.
India is the developing country. India is a densely populated country with
the vehicle usage being really diverse. While the available resources which are
used to run the vehicles like road quality & new technologies in vehicles are
being developed to avoid accidents. The number of people expired during
vehicle accidents is very large as compared to the other causes of death. Though
there are different causes for accidents but proper technology of braking system
and technology to reduce the damage during accident should be developed.
As similar to above technology, this system must be designed to
minimize the effects of these accidents. The aim of the present study is to
design a device which can successfully scan the surroundings during driving
and apply brake to avoid front end collision of the vehicle, along with extension
of bumper. This bumper actuation system has operates automatically.
Automation can be achieved through computers, hydraulics, pneumatics,
robotics, etc., of these sources, pneumatics for man attractive medium for low
cost automation. The main advantages of all pneumatic systems are economy
and simplicity.
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Fig 1.1 Technologies in Automobiles
1.3NEED FOR AUTOMATION
Robotization can be accomplished through PCs, water power,
pneumatics, apply autonomy, and so on. Of these sources, pneumatics frames an
alluring medium for minimal effort mechanization. The principle points of
interest of every single pneumatic system are economy and effortlessness.
Mechanization assumes a critical part in large scale manufacturing. For large
scale manufacturing of the item, the machining operations choose the
succession of machining. The machines intended for creating a specific item are
called exchange machines. The parts must be moved naturally from the
receptacles to various machines consecutively and the last segment can be put
independently to package. Materials can likewise be over and again exchanged
from the moving transports to the work place and the other way around. These
days all the assembling procedure is being atomized with a specific end goal to
convey the items at a quicker rate.
The assembling operation is being atomized for the accompanying
reasons.
To achieve mass production
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To reduce man power
To increase the efficiency of the plant
To reduce the work load
To reduce the production cost
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including robotics, aerospace technology, production andassembly of
automotive components (power steering, chassis and engine assembly), CNC
machines, food products and packaging industry, bomb deployment units and
fabrication process of plastic products.
1.3.2 PROCESS OF PNEUMATIC SYSTEM
The generalized pneumatic system consists of an air compressor, which
delivers air to a pressurereservoir (accumulator). High-pressure line is tapped
from the reservoir and fed to the Filer-Regulator-Lubricator (FRL) unit where
the air is filtered, lubricated and the pressure is regulated. The air from theoutlet
of the FRL unit enters the relief valve, which protects the system and bleeds air
to atmosphere ifthe working pressure exceeds the safe pre-set value.
The pressure gauge mounted on the relief valve isused to monitor the
working pressure of the system. Flexible hoses connect the outlet port of the
reliefvalve and the inlet port of a pneumatic Direction Control Valve (DCV).
This valve can be actuatedmechanically, manually, or by electrical solenoids.
A pneumatic PLC controls the valve using thesolenoid. When the left
solenoid of the DCV is energized by the PLC, the piston in the
pneumaticcylinder (actuator) moves outward and energizing the right solenoid
valve cause the piston to move inward.The piston stops when both the solenoids
are de-energized. This process is a timer based control in the PLC.
1.4 INTRODUCTION TO BRAKING SYSTEM
1.4.1 BRAKE SYSTEM
A brake is a mechanical device which inhibits motion. The rest of this
article is dedicated to various types of vehicular brakes. A vehiclebrake is a
brake used to slow down a vehicle by converting its kinetic energy into heat.
The basic hydraulic system, most commonly used, usually has six main stages.
The brake pedal, the brake boost (vacuum servo), the master cylinder, the
apportioning valves and finally the roadwheel brakes themselves.
1.4.2 TYPES OF BRAKING SYSTEM
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1.4.2.1 FRICTION BRAKE
A friction brake is a type of automotive brake that slows or stops a
vehicle by converting kinetic energy into heat energy, via friction. The heat
energy is then dissipated into the atmosphere. In most systems, the brake acts on
the vehicle's road wheel hubs, but some vehicles use brakes which act on the
axles or transmission. Friction brakes may be of either drum or disc type.
A drum brake is a vehicle brake in which the friction is caused by a set of
brake shoes that press against the inner surface of a rotating drum. The drum is
connected to the rotating road wheel hub. The disc brake is a device for slowing
or stopping the rotation of a road wheel. A brake disc, usually made of cast iron
or ceramic, is connected to the wheel or the axle. To stop the wheel, friction
material in the form of brake pads (mounted in a device called a brake caliper)
is forced mechanically, hydraulically, pneumatically or electromagnetically
against both sides of the disc. Friction causes the disc and attached wheel to
slow or stop.
Most commonly brakes use friction to convert kinetic energy into heat,
though other methods of energy conversion may be employed. For example
regenerative braking converts much of the energy to electrical energy, which
may be stored for later use. Other methods convert kinetic energy into potential
energy in such stored forms as pressurized air or pressurized oil. Eddy current
brakes use magnetic fields to convert kinetic energy into electric current in the
brake disc, fin, or rail, which is converted into heat. Still other braking methods
even transform kinetic energy into different forms, for example by transferring
the energy to a rotating flywheel. Brakes are generally applied to rotating axles
or wheels, but may also take other forms such as the surface of a moving fluid
(flaps deployed into water or air). Some vehicles use a combination of braking
mechanisms, such as drag racing cars with both wheel brakes and a parachute,
or airplanes with both wheel brakes and drag flaps raised into the air during
landing.
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mv 2
Since kinetic energy increases quadratic allywith velocity K= , an
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object moving at 10 m/s has 100 times as much energy as one of the same mass
moving at 1 m/s, and consequently the theoretical braking distance, when
braking at the traction limit, is 100 times as long. In practice, fast vehicles
usually have significant air drag, and energy lost to air drag rises quickly with
speed.
Almost all wheeledvehicles have a brake of some sort. Even baggage
carts and shopping carts may have them for use on a moving ramp. Most fixed-
wing aircraft are fitted with wheel brakes on the undercarriage. Some aircraft
also feature air brakes designed to reduce their speed in flight.
Friction brakes on automobiles store braking heat in the drum brake or
disc brake while braking then conduct it to the air gradually. When traveling
downhill some vehicles can use their engines to brake. When the brake pedal of
a modern vehicle with hydraulic brakes is pushed, ultimately a piston pushes the
brake pad against the brake disc which slows the wheel down. On the brake
drum it is similar as the cylinder pushes the brake shoes against the drum which
also slows the wheel down. Brakes may be broadly described as using friction,
pumping, or electromagnetic. One brake may use several principles: for
example, a pump may pass fluid through an orifice to create friction. Frictional
brakes are most common and can be divided broadly into “shoe” or “pad”
brakes, using an explicit wear surface, and hydrodynamic brakes, such as
parachutes, which use friction in a working fluid and do not explicitly wear.
Typically the term “friction brake” is used to mean pad/shoe brakes and
excludes hydrodynamic brakes, even though hydrodynamic brakes use friction.
Friction brakes are often rotating devices with a stationary pad and a
rotating wear surface. Common configurations include shoes that contract to rub
on the outside of a rotating drum, such as a band brake; a rotating drum with
shoes that expand to rub the inside of a drum, commonly called a “drum brake”,
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although other drum configurations are possible; and pads that pinch a rotating
disc, commonly called a “disc brake”. Other brake configurations are used, but
less often.
1.4.2.2 PUMPING BRAKES
Pumping brakes are often used where a pump is already part of the
machinery. For example, an internal-combustion piston motor can have the fuel
supply stopped, and then internal pumping losses of the engine create some
braking. Some engines use a valve override called a Jake brake to greatly
increase pumping losses. Pumping brakes can dump energy as heat, or can be
regenerative brakes that recharge a pressure reservoir called a hydraulic
accumulator.
1.4.2.3 ELECTROMAGNETIC BRAKES
Electromagnetic brakes are likewise often used where an electric motor is
already part of the machinery. For example, many hybrid gasoline/electric
vehicles use the electric motor as a generator to charge electric batteries and
also as a regenerative brake. Some diesel/electric railroad locomotives use the
electric motors to generate electricity which is then sent to a resistor bank and
dumped as heat. Some vehicles, such as some transit buses, do not already have
an electric motor but use a secondary “retarder” brake that is effectively a
generator with an internal short-circuit. Related types of such a brake are eddy
current brakes, and electro-mechanical brakes (which actually are magnetically
driven friction brakes, but nowadays are often just called “electromagnetic
brakes” as well).
A disc brake is a wheel brake which slows rotation of the wheel by the
friction caused by pushing brake pads against a brake disc with a set of calipers.
The brake disc (or rotor in American English) is usually made of cast iron, but
may in some cases be made of composites such as reinforced carbon–carbon or
ceramic matrix composites. This is connected to the wheel and/or the axle. To
stop the wheel, friction material in the form of brake pads, mounted on a device
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called a brake caliper, is forced mechanically, hydraulically, pneumatically or
electromagnetically against both sides of the disc. Friction causes the disc and
attached wheel to slow or stop. Brakes convert motion to heat, and if the brakes
get too hot, they become less effective, a phenomenon known as brake fade. On
automobiles, disc brakes are often located within the wheel.
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CHAPTER 2
LITERATURE REVIEW
Guo Lie et al., (Jul 2014), According to the requirement of the collision
avoidance control system, the safety status was judged by comparing the
current distance between the host vehicle and the obstacle with the critical
braking distance.Then the vehicle dynamics model and the vehicle inverse
longitudinal dynamics model were established in CarSim. The collision
avoidance controllerwas designed based on slidingmode and single neuron
PID method, realizing automatic braking control of the host vehicle for
vehicle or pedestrian collision avoidance and guaranteeing the active safety
of the vehicle.The parameters of the experimental vehicle were applied to the
vehiclemodel utilizing CarSim, which could better reflect nonlinear
timevarying characteristics and control effect of the longitudinal dynamics,
possessing a certain practical significance and research value. Finally,
cosimulations were carried out on a CarSim vehicle model utilizing
Matlab/Simulink to explore the effectiveness of the proposed controller.
Results indicate that the controller can realize the deceleration or emergency
brake when there is a pedestrian or vehicle ahead of the host vehicle.
However, more possible collision avoidance scenarios should be taken into
account. Additionally, the proposed controller should be applied to the real
intelligent vehicle prototype which also can deal with the emergency
situation of more collision avoiding scenarios and consider other measures
like braking and lane changing at the same time in the future work.
Sandeep Thorat et al., (Mar 2016), If we can reduced the Driving
Interference of Braking and Give the Responsibility To Intelligence Sensor
which will Take decision and initiate the Response To give Warning alarm
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First and if Distance of impact is Closing it will Apply brake Automatically
and Stop the Vehicle in advanced. Such that Distraction Driving is a Major
Contributor to Accident death, thus by implementing this System we can
reduced the Close impact Potential Accident. By dragging the front seat at
opposite direction to Impact and increase the Distance And Time Of Direct
Impact the death can be minimized and safety of vehicle also can improved,
and also it can add the new feature to the car which will attract the customer
who prefer safety while traveling. The results of the simulations showed that
by using an energy absorbing seating system, crash deceleration can be
effectively attenuated and occupant injuries significantly reduced in
comparison to conventional seating systems. In future, physical crash tests
will still be required as the final certification method for approval of a
particular crashworthy mechanical system. However during the development
process the application of computer simulation methods as presented in this
paper show that it is possible to reduce development costs.
Dineshkumar C, Subramanian M (2017), Automated safety systems
besides enhancing active safety devices due to increased rate of accidents in
India. Accidents systems had been incorporated only in high class vehicles
and modern vehicles. The propose system should be useful for the middle
class peoples and low end vehicles. The proposed system would be cost
effective and the stepper motor is used to operate the brake cable to control
the impact. The system is designed to reduce the speeds of the vehicle and to
slow down the vehicle before collision. The impact of the vehicle is reduced
and the braking efficiency is increased during critical situation. The life of
driver and co-passenger is saved and injury is reduced by using this system.
Shubham Pawar et al., (Dec 2017), Automatic brake with pneumatic
bumper system is an additional safety to heavy vehicles with passenger car .
It is easy to make such a system in heavy air brake vehicles. An emergency
switch is provided for emergency uses . This switch avoids the driver to stand
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from his seat. The system carried out by us made an impressing task in the
field of automobile manufacturing industries. It is very useful for the workers
work in the lath and small scale industries. This system will reduce the cost
involved in the concern. system can be design to perform the entire
requirement task at the shortest time available.
Ashwini A. Kamble et al., (2017), In the present work, it is investigated
that the tremendous growth has continuously risen in demand for automobile
and automotive sector. In the view of this, we need to advance our
technology regarding light and heavy duty vehicles. The necessity of
automatic breaking system is designed and implemented by pneumatic
principle. Automatic brake with the pneumatic bumper system is an
additional safety to heavy vehicles with a passenger car. It is easy to make
such a system in heavy air brake vehicles. An emergency switch is provided
for emergency uses.This switch avoids the driver to stand from his seat. The
project carried out by us made an impressing task in the field of automobile
manufacturing industries. It is very useful for the workers work in the lath
and small scale industries. This project will reduce the cost involved in the
concern. The project has been designed to perform the entire requirement
task at the shortest time available.
Umar Zakir Abdul Hamid et al., (Mar 2018), In this work, as an
improvement to the available Autonomous Emergency Braking system, the
authors proposed an integrated AEB system with the Potential Field Risk
Assessment strategy to prevent the near-miss incidents. A real-time
validation experiment of the aforementioned system is done on a research
vehicle platform. PF successfully measure the risk of the frontal static
obstacle. Based on the risk measurement, the host vehicle subsequently
yielded the desired braking actuations percentage to allow it for a full vehicle
stopping. The inclusion of PF into the AEB allow iDrive to maintain the safe
distance of 2 m to the frontal obstacle. However, due to safety issues and
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limited size of the testing area, the system is only validated with medium
speed. For future works, more complex scenarios and higher speed host
vehicle will be used for the validation of the system. Varied driving behavior
patterns in the emergency braking scenario by different drivers should also be
studied to enhance the AEB performance. Concluding the work, this research
is beneficial as it will allow more development of a fully autonomous vehicle
for future works.
A M Ivanov et al., (2018), The results of experimental studies of the
"AEBS" of "Infiniti QX 60 Hi-tech" automobile model give us a possibility
to make such conclusions: Means of technical vision of the "AEBS" object
recognize the type of the "target" the "soft wall" as an obstacle. This "target"
can be applied during future tests. Means of technical vision of "AEBS"
object recognize badly object type "target" a "stationary bicycle". This aspect
restricts the range of functional safety of the "AEBS". The deceleration
achieved by the object during the operation of the "AEBS" is not enough for
the complete stop of the object in front of a static obstacle, which also
reduces the effective range value of the system. The collision warning signal
algorithm does not depend on grip properties of the road surface. This fact
reduces the functional safety of the "AEBS" on slippery surfaces. A large
number of the "AEBS" failures at a speed of 80 km/h indirectly indicate an
insufficient distance value to detect the obstacle. This matter also reduces the
range of application of the "AEBS". There was not recorded an "AEBS"
"false target" action.
Dineshkumar C et al., (Aug 2019), The proposed system senses the
object detection which is present in front of the vehicle. Whenever the
sudden object detection is detected the speed of the vehicle is reduced by
applying the brake gradually after the warning signal. The velocity of the
vehicle is reduced by using hydraulic actuator which is connected to brake
pedal to compress during emergency. The stopping distance is calculated for
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the proposed system and the automatic braking is activated before vehicle
impacts. The proposed system reduces the collision and damage to the
vehicle.
Nikhil Umakant Rane et al., (Oct 2019), Autonomous Emergency
Braking system with laser is an additional safety to light duty vehicle as well
as heavy vehicles with passenger car. It is easy to make such a system in
brake assist system vehicles. An emergency switch is provided for
emergency uses. The system carried out by us made an impressing task in the
field of automobile manufacturing industries. This system will reduce the
accidents happens on the roadways. Is also reduces the braking distance of
the vehicle.
Chen Chao and Xia Qin, The introduction of analytic hierarchy process
(AHP), analytic hierarchy structure model is established, a target vehicle
static condition, target vehicle at low speed conditions, working condition of
a target vehicle deceleration condition and target vehicle bias conditions,
change lanes rule of five layers. According to the hierarchical structure
model, respectively, set up the total target layer relative to the criterion of
judgement matrix and guidelines for each scheme layer of judgment matrix.
Calculates the maximum characteristic value of each judgment matrix and
weight. Calculated according to the theory of analytic hierarchy process
(AHP) consistency judging the consistency of judgment matrix is good. The
last increase AEBS HMI, false alarm and bonus evaluation method.
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CHAPTER 3
PROBLEM IDENTIFICATION
3.1 CURRENT TRENDS
In conventional vehicles there are different mechanism operated for
braking system like hydraulic, pneumatic, or mechanical system. But in all these
braking mechanisms the input signal is to be given directly from the driver by
applying the brake pedal. Thus, braking of vehicles is totally manual operated.
So, if the driver fails to see the obstacle in front of his driving vehicle or fails to
apply proper braking force on the brake pedal, he may lose the control of his
vehicle, leading to accident. Also the driver may not able to pay complete
attention when driving at night. So there are many chances of accidents. Urgent
application of brakes may also result in imbalance by skidding of the tyres of
the vehicle. So, there are no arrangements to prevent or minimize the damage
on the vehicle or the passengers.
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CHAPTER 4
METHODOLOGY
Existing method
Proposed method
Design
Component Selection
Fabrication
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4.1 COMPONENTS USED
The followings are the components to be used to fulfill the requirements
of our project,
Pneumatic Cylinder
Solenoid Valve
Control Unit
Ir Sensor
Motor
Toggle Switch
Battery
Wheel
Frame
Connectors And Pu Tubes
4.2 OBJECTIVE OF THE PROJECT
The main objectives of Impact Reduction System with Pneumatic Bumpers:-
To ensure the braking of vehicle in time.
To increase the crashing distance during accident.
To increase the safety during pre-crash.
To increase external safety to vehicle body.
To decrease the level of passenger injury by use of external vehicle safety
device.
To reduce the requirement of internal safety devices like air bags.
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CHAPTER 5
COMPONENTS DESCRIBTION
5.1 PNEUMATIC CYLINDER
Once actuated, compressed air enters into the tube at one end of the
piston and imparts force on the piston. Consequently, the piston becomes
displaced.
In our system, we may use both single acting cylinder and double acting
pneumatic cylinder. The single acting cylinder is used for braking purpose and
double acting cylinder for bumper movement.
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some spring-loaded cylinders the spring is located on the blank side, and
the fluid port is on the rod side of the cylinder.
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Fig 5.2 Working of Single Acting Cylinder
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5.2 SOLENOID VALVE
The magnetic plunger acts directly on the valve seal to open or close the
valve orificedepending upon whether the solenoid is energized or de-energized.
The pressure andflow capability of this type of solenoid valve depend directly
on the orifice size and thecoil power. Direct acting solenoid valves are rarely
used on their own to controlpneumatic actuators as although they can usually
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handle the pressure, the orifice sizerestricts the flow rate to the actuator and
limits its speed of operation.Solenoid valves can be used for a wide array of
industrialapplications, including general on-off control, calibrationand test
stands, pilot plant control loops, processcontrol systems, and various original
equipment manufacturerapplications.
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removes the ripples and also remains the same dc value even if the input dc
voltage varies, or the load connected to the output dc voltage changes.
REGULATOR
5.3.1.1 TRANSFORMER
The potential transformer will step down the power supply voltage (0-
230V) to (0-6V) level. Then the secondary of the potential transformer will be
connected to the precision rectifier, which is constructed with the help of op-
amp. The advantages of using precision rectifier are it will give peak voltage
output as DC; rest of the circuits will give only RMS output.
5.3.1.2 RECTIFIER
When four diodes are connected as shown in the power supply circuit
diagram, is called Bridge rectifier. The input to the circuit is applied to the
diagonally opposite corners of the network, and the output is taken from the
remaining two corners.
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Voltage regulators comprise a class of widely used ICs. Regulator IC
units contain the circuitry for reference source, comparator amplifier, and
overload protection all in a single IC. IC units provide regulation of either a
fixed positive voltage, a fixed negative voltage, or an adjustable set voltage. The
regulators can be selected for operation with load currents from hundreds of m
amp to tens of amperes, corresponding to power ratings form milli watts to ten
watt. A fixed three-terminal voltage regulator has an unregulated dc input
voltage, Vi, applied to one input terminal, a regulated dc output voltage, Vo ,
from a second terminal, with the third terminal connected to ground.
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strong electric field or flow of electric current is called electroluminescence. A
normal p-n junction diode allows electric current only in one direction. It allows
electric current when forward biased and does not allow electric current when
reverse biased. Thus, normal p-n junction diode operates only in forward bias
condition. Like the normal p-n junction diodes, LEDs also operates only in
forward bias condition. To create an LED, the n-type material should be
connected to the negative terminal of the battery and p-type material should be
connected to the positive terminal of the battery. In other words, the n-type
material should be negatively charged and the p-type material should be
positively charged.
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Fig 5.6 IR Sensor
Most PIR sensors have a 3-pin connection at the side or bottom. One pin
will be ground, another will be signal and the last pin will be power. Power is
usually up to 5V. Sometimes bigger modules don’t have direct output and
instead just operate a relay which case there is ground, power and the two
switch associations. Interfacing PIR with microcontroller is very easy and
simple. The PIR acts as a digital output so all you need to do is listening for the
pin to flip high or low. The motion can be detected by checking for a high
signal on a single I/O pin. Once the sensor warms up the output will remain low
until there is motion, at which time the output will swing high for a couple of
seconds, then return low. If motion continues the output will cycle in this
manner until the sensors line of sight of still again. The PIR sensor needs a
warm-up time with a specific end goal to capacity fittingly. This is because of
the settling time included in studying nature’s domain. This could be anyplace
from 10-60 seconds.
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Fig 5.7 schematic diagram for IR sensor
5.4.1 APPLICATIONS
5.4.2 FEATURES
5.5 DC MOTOR
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The electric wiper motor is a permanent magnet, rotary electric motor. A
worm gear machined on the armature shaft drives the output shaft and gear
through an idler gear and shaft. The output shaft operates the output arm, which
is connected to the wiper linkage. As the electric motor revolves the output arm,
the linkage is forced to move in a back and forth motion.
In case of two speed motor, the high speed is obtained when the current is
supplied to the brush g and brush 1 as in Fig . By Fleming's right hand rule the
current, force and the magnetic fields are mutually perpendicular to each other.
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In this motor as the current is supplied to the brush 1 and brush g, the magnetic
field is generated perpendicular to the armature shaft. This induces a force in the
armature which makes the armature to rotate. Since, the magnetic fields
generated are opposite to each other the shaft rotates at a high speed. In the
second speed the brush 2 and brush g gets magnetized. Since the magnetic fields
produced by them are at perpendicular to the force generated on the copper
winding, will be less than the force generated by the brush 1 and brush g. This
makes the armature shaft to rotate at a lower speed.
In order for the wiper motor to move it needs a power source. The
different power sources are the car batteries, voltages (12volts DC), current
(minimum of 1.6 amps at 70 rpm; 1 amps at 41 rpm), computer batteries
(12volts output) and other battery supplies that doe does not exceed the limit of
12 volts otherwise the motor is bound to overheat.
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12 Volts / 24 Volts
60 Wipes per minute on load (High speed)
RF suppression optional
Single speed / two speed with thermal cut out
40 Wipes per minute on load (Normal speed)
Here, the poles and throws can be defined as; when the number of circuits
is controlled by a switch is called poles, whereas throws can be defined as the
number of positions that the switch can adopt. A single throw switch consists
one pair of contacts like open or close. A double throw switch includes a
contact, which can be connected to two other contacts. When the switch is
activated, then the current flows through between the two terminals of the
switch. When the switch is OFF, then the current doesn’t flow between the two
terminals of the switch.
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DPDT (double pole double throw)
The SPDT switch is a three terminal switch, one terminal is used as input
and remaining two terminals are used as outputs. It joins a mutual terminal to
one or the other of two terminals. In the SPDT switch, instead of other
terminals, just use COM terminal. For example, we can use COM & A or COM
& B.
5.7 BATTERY
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positive electrode. The electrolyte may be aqueous (composed of water) or non-
aqueous (not composed of water), in liquid, paste, or solid form. When the cell
is connected to an external load, or device to be powered, the negative electrode
supplies a current of electrons that flow through the load and are accepted by
the positive electrode. There are two types of battery that commonly use which
are primary batteries (disposable battery) and secondary batteries (rechargeable
battery).
The lead-acid battery is the most commonly used type of storage battery and is
well-known for its application in automobiles. The battery is made up of several
cells, each of which consists of lead plates immersed in an electrolyte of dilute
sulfuric acid. The voltage per cell is typically 2 V to 2.2 V. For a 6 V battery,
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three cells are connected in series, and for a 12 V battery, six cells are series
connected.
When the lead-acid cell is charged, the lead oxide on the positive plate
changes to lead peroxide, and that on the negative plates becomes a spongy or
porous lead. In this condition, the positive plates are brown in colour, and the
negative plates are grey.
5.7.1.3 FEATURES
5.8 WHEEL
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Common examples are found in transport applications. A wheel greatly
reduces friction by facilitating motion by rolling together with the use of axles.
In order for wheels to rotate, a moment needs to be applied to the wheel about
its axis, either by way of gravity or by the application of another external force
or torque.
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This frame structure is a base of our prototype model and it give shape
our desire machines. We use material for this frame structure is mild steel
because its material properties are suitable for our construction.
The pneumatic circuit is connected using tubes which will transfer the
compressed air from compressor and the solenoid valve. The solenoid valve is
connected with the single acting pneumatic cylinder using these tubes only.
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Fig 5.12 pu tube for air flow
The electric wires are used to transfer input signal from control unit to
solenoid valve and to provide power supply to the pneumatic circuit. 1s core
wire has been used for transforming electrical power from the battery to the dc
motor.
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CHAPTER 6
WORKING PRINCIPLE
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CHAPTER 7
MACHINING PROCESS
The prototype model is fabricating with some manufacturing process and
those few operations are described below:
Cutting
Welding
Drilling
Assembly
Painting
7.1 CUTTING PROCESS
Cutting is a collection of processes wherein material is brought to a
specified geometry by removing excess material using various kinds of tooling
to leave a finished part that meets specifications. We have make materials to
require shape from raw materials by using cutting process. A few cutting
methods of materials are described below as an images. L-angle and sheet metal
has been cutted by this machine for our requirements.
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Fig 7.1 Cutting Machine
7.2DRILLING OPERATION
Drilling is a cutting process that uses a drill bit to cut a hole of
circular cross-section in solid materials. The drill bit is usually a rotary cutting
tool, often multi-point. The bit is pressed against the work-piece and rotated at
rates from hundreds to thousands of revolutions per minute. This forces the
cutting edge against the work-piece, cutting off chips from the hole as it is
drilled. Wooden plates drilled by tis drilling machine for fixing circuits with
structural frame.
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Fig 7.2 Drilling Machine
7.3WELDING PROCESS
Welding is a fabrication or sculptural process that joins materials, usually
metals or thermoplastics, by causing fusion, which is distinct from lower
temperature metal-joining techniques such as brazing and soldering, which do
not melt the base metal.
Here we use welding process mostly for fabrication of steel structures. So
we select arc welding method of welding process in manufacturing.
Arc welding is a process that is used to join metal to metal by using
electricity to create enough heat to melt metal, and the melted metals when cool
result in a binding of the metals. It is a type of welding that uses a welding
power supply to create an electric arc between an electrode and the base
material to melt the metals at the welding point. They can use either direct (DC)
or alternating (AC) current, and consumable or non-consumable electrodes. The
welding region is usually protected by some type of shielding gas, vapour, or
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slag. Arc welding processes may be manual, semi-automatic, or fully
automated. First developed in the late part of the 19th century, arc welding
became commercially important in shipbuilding during the Second World War.
Today it remains an important process for the fabrication of steel structures and
vehicles.
7.4ASSEMBLY PROCESS
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Fig 7.4 Assembly Work
7.5 PAINTING
Paint is one major segment of the surface coatings, which also includes
varnishes, enamels, printing inks and polishes. The paint industry produces a
huge variety of products that protect, preserve, and also beautify the objects to
which they are applied. Typical products include architectural coatings (e.g.
house paints), industrial coatings (e.g. automotive finishes, wood furniture and
fixture finishes), and special purpose coatings (e.g. traffic paints, roof coatings).
The objective of painting is to form a coating film on the surface of an
object in order to protect the object and give a fine appearance. Painting may
also have other special functions. There are various types of painting methods,
and spray painting is currently used in many types of industrial painting.
“Spray painting” consists of the painting operation itself followed by
coated film drying. The paint used in the painting process is diluted with
thinner, and solid portions in the paint form the coating film after the spraying
operation.
CHAPTER 8
MERITS AND APPLICATION
8.1 MERITS
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It reduces the vehicle accidents.
Braking system able to give fast response.
System able to increase the pre-crash safety.
This system increases the response time of vehicle braking by keeping
safe distance between two vehicles.
8.2APPLICATIONS
This system may be applicable in all types of light vehicles like cars,
Rickshaws.
This system also successfully installed in theheavy vehicles like buses,
trucks, trailers, etc.
CHAPTER 9
CONCLUSION
This project work has provided us an excellent opportunity and
experience, to use our limited knowledge. We are feeling that we have
completed the work within time successfully. The"FABRICATION OF
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EMERGENCY BRAKING SYSTEM" is working with satisfactory
conditions. The main concluded of this project is reduces the sudden vehicle
accidents by using the pneumatic brake. Sensors are used to detect the speed
and distance of between vehicles.
CHAPTER 10
FUTURE SCOPE
Our future work deals with incorporating this system with various
different features to provide enhanced protection by the advanced intelligent
46
braking system in real time application. For that, some of the possible changes
are:
REFERENCES
47
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