4. Project Report Intelligent Breaking System 2

Intelligent Braking System Page 1 of 30

CHAPTER ONE

INTRODUCTION

1.1 Need Of New System:

We have pleasure in introducing our new project INTELLIGENT BRAKING

SYSTEM, which is fully equipped by IR sensors circuit and Pneumatic braking circuit.

It is a genuine project which is fully equipped and designed for Automobile vehicles.

This forms an integral part of best quality. This product underwent strenuous test in our

Automobile vehicles and it is good.

The SENSOR OPERATED BRAKING SYSTEM can stop the vehicle within 2 to

3 seconds running at a speed of 50 KM. The intelligent braking system is a fully automation

project. This is an era of automation where it is broadly defined as replacement of manual

effort by mechanical power in all degrees of automation. The operation remains an essential

part of the system although with changing demands on physical input as the degree of

mechanization is increased.

Degrees of automation are of two types, viz.

1. Full automation.

2. Semi automation.

In semi automation a combination of manual effort and mechanical power is required

whereas in full automation human participation is very negligible.

Braking systems of commercial vehicles were always given the highest importance

concerning safety issues and in particular active safety. Due to different design and load

characteristics of these vehicles, different performance of their braking system especially

related to different wheel brakes and their tribological behavior are the main reasons why the

operation of their braking systems should be constantly monitored and controlled depending

on the drivers demands and the adhesion characteristics between tyres and road.

Inappropriate braking of these vehicles may cause heavy accidents due to relatively longer

stopping distances and higher energy output of brakes particularly in the case of vehicle

combinations.


Ever-increasing demands in term of responsiveness and control are being made on system for

brake and chassis management in commercial vehicles. The traditional medium used for brake

system (compressed air) can be now controlled with the speed and precision offered by

modern electronic abilities. Intelligent Braking System going to introduced in commercial

vehicles providing rapid brake response during parking for drivers and vehicle safety.

1.2 Objectives:

Intelligent Braking System has objectives as per following:

[1] As there is always problem regarding with parking of vehicle properly and with minimum

time.

[2] Many time driver unable to judge the proper distance between back side of vehicle and

obstacle during parking.

This parking problem tends to damage of vehicle most of time and cause

critical accident.

To provide safe parking.

To avoid damage of vehicle.

To provide comfort for driver with regarding parking purpose.

1.3 Functions:

Intelligent Braking System provides many useful functions:

1. It will provide safety for driver.

2. It will provide safety for rear side of vehicle during parking.

3. It will judge the proper and required distance between back side of vehicle and wall

for parking.

4. It will immediately give control signal to apply brake instantly.


CHAPTER TWO

LITERATURE REVIEW

2.1 Project plan:

Intelligent Braking System means a braking system that provides a safety for vehicle

during the parking of vehicle in parking area. Many time it seems that the driver unable to

judge the obstacle at back side of vehicle during the parking of vehicle.

So, Intelligent Braking System introduced with the feature that avoid the damaging of vehicle

during the parking process.

The project, Intelligent Braking System is planning to introduce a new advanced system in

automobile market. Damaging During a parking of vehicle is quite major problem but until

there is no solution on this problem. So we introduced a new system that will avoid damaging

of vehicle during parking.

Intelligent Braking System will open up new and promising opportunities to engineer in

order of safety and discipline. Basic human being are many time unable to judge the accurate

and safe required distance during the parking in parking area.

2.2 Project scope:

Intelligent Braking System is introduced for providing safety and comfort to driver during

parking of car. The main aim of system is to avoid critical damage of vehicles at the time

parking. Most of time drivers unable to judge proper distance between car and obstacle, so

this system will helpful as well as important in car safety.

The intelligent braking system will open up a new ideas and concepts for automobile

industry

As the requirements of human beings for comfort and safe driving are increases. This system

is addition in regular safety system. And also increases the demand of vehicle in market view.

2.3 Resources:

For the making and developing of this project many raw materials, main components such

as 5/2 DC valve, pneumatic cylinder, connecting wires and tubes were required in list.

Required material for project were obtained from different hardware shops, electrical shop

and from near workshop. For making of this project, 5/2 dc valve, polyurethane tube, tube

connectors pneumatic cylinder were purchased from nearby hardware store.


The frame material such mild steel angles and plates were purchased and obtained from

workshop.

Electronic equipments such as IR sensor, control circuit for valve were made by an skilled

electronic engineer and adapter for external power supply of DC motor, IR sensor and control

circuit were purchased from nearby electronic shop.

Welding of frame was done in welding workshop, circuit for control unit and sensor were

made by with the help of an electronic and telecommunication engineer.


CHAPTER THREE

SYSTEM MODELING

Intelligent Braking System

Figure.3.1: Construction Detail

3.1 Constructional feature:

Whole assembly of Intelligent Braking System consists of following main parts:

3.1.1. Frame: Frame is made up of 40C8 material. Frame is generally made up in order of

required dimensions.

Dimension of frame:

Length: 500mm

Width: 400mm

Height: 150mm


3.1.2. Pneumatic Cylinder:

One pneumatic cylinder for braking purpose. Cylinder is mounted on rectangular bar.

Specification of cylinder:

Cylinder Sr. No. - 30825-95166

Bore:- 25mm

Stroke: - 50mm

3.1.3. Solenoid Valve:

One solenoid valve of 5/2 DC valve for controlling of pneumatic cylinder. Valve consists of

5 ports and 2 positions. Valve is mounted on frame and valve ports are connected to cylinder

by using polyurethane tube.

3.1.4. D.C. Motor:

One D.C. motor is mounted on one wheel to provide free rotation of wheels.

Specification of motor:

Torque: 200rpm

Volt: 12V DC

3.1.5. IR sensor and control unit:

IR sensor unit is mounted at back side of frame. External power supply is provided to IR

sensor. Control unit is connected to solenoid valve in order to actuation of valve.

3.1.6. Working Wheel:

Two working wheels of free rotation are mounted on both end of metal shaft. Two ball

bearings are provided for smooth rotation of both wheels and both ball bearings are mounted

on rectangular bar.


3.2 Working of system

Intelligent Braking System is work on principle of working of clutch and braking system

through pneumatic pressure which is equipped by using IR sensor circuit.

Wheels are continuously rotating in clockwise direction as the motor is connected to the

wheel.

IR circuit consists of one transmitter called as IR Transmitter and one receiver called as

IR Receiver. IR Transmitter continuously transmitting the Infra Red rays. If any obstacle

is there in a path, the Infra-Red rays reflected. This reflected Infra-Red rays are received by

the IR Receiver. The IR Receiver circuit receives the reflected IR rays and giving the control

signal to the control circuit. The control circuit is used to activate the solenoid valve.

As the solenoid valve activated it will allow passing the air from compressor to cylinder

through the connecting tube.

High pressure of air move the piston to outside of the cylinder and shaft of the piston come in

contact of rotating wheel and thus brake applies and wheel stop rotating.

Figure.3.2: Flow diagram of system

AIR COMPRSSOR

CONTROL UNIT

POWER SUPPLY

SOLENOID VALVE

PNEUMATIC CYLINDER

IR TRANSMITTER

IR RECEIVER

BRAKE APPLY

FLOW CONTROL VALVE


3.3 Component diagram System consists of following main component:

1. Frame

2. Pneumatic Cylinder

3. Solenoid valve

4. D.C. Motor

5. IR Sensor

3.3.1. Frame:

Figure.3.3: Frame

Dimension of frame:

Length: 500mm

Width: 400mm

Height: 150mm


3.3.2 Pneumatic cylinder:

Figure3.4: Pneumatic cylinder

Specification of cylinder:

Cylinder Sr.No.:30825-95166

Bore:-25mm

Stroke:-50m

3.3.3 Solenoid Valve:

Figure.3.5: 5/2 dc valve


Specification 5/2 DC VALVE:

P = inlet port of valve

A and B = work passages port of valve

R1 = air exhaust port 1

R2 = air exhaust port 2

Symbol of 5/2 DC Valve:

Figure3.6: Symbol of 5/2 dc valve

3.3.4. DC Motor:

Figure.3.7: DC motor


Specification of DC motor:

Voltage : 12 VDC

Output Power: 1.1 W

Gear Ratio : 1:20 or 1:60

For Gear Ration

Rated Speed: 200 RPM (for gear ratio 1:20)

58 RPM (for gear ratio 1:60)

Rated Torque: 7.84 N.cm (for gear ratio 1:20)

25.4 N.cm (for gear ratio 1:60)

Rated Current: 0.41 A

Encoder Resolution: 60 counts per revolution

Weight: 160 g

Diameter: 37 mm

Shaft diameter: 5.5 mm

3.3.5. IR Sensor:

Figure.3.8: IR sensor


3.3.6. Compressor:

Figure.3.9: Compressor


3.4 Material requirement

Used materials and their properties:

The materials used in this project are detailed as follows:

Ferrous materials

MILD STEEL

EN-4 TO EN-6

[1]Carbon- 0.15% to 0.35%

[2]Tensile strength-1200/1420 MPA

[3]Yield strength-750/1170 MPA

40C8

[1]Vehiclebon-0.25% to 0.35%

[2]Tensile strength-620 MPA

[3]Yield strength-400 MPA

Non metallic materials

The non metallic materials are use in engineering practice due to their low density, low cost,

flexibility, resistance to heat and electricity. Though there are many non metallic materials,

important materials used in our project are list below:

Rubber

It is one of the most important natural plastics. It resists abrasion, heat, strong alkalis, and

fairly strong acids. Soft rubber is used for electrical insulations. It is also used for power

transmission belting, being applied to woven cotton as a base. The hard rubber is used for

piping and as lining for pickling tanks dimensional stability. They are mostly use in

manufacture of aero planes and automobile parts. They are also used for making safety

glasses, laminated gears.


The system consists of following materials:

1. Angle of cast iron material selected for frame purposed. Angle of 255 selected for frame.

Angles cut in following dimensions:

2 Nos. 500mm in length



All these parts are welded together in order to making of frame for supporting all assembly of

system.

2. Two rectangular bar used for supporting of wheel shaft, cylinder and bearings.

Both bars are made up cast iron material. Bar in size of 120mm50mm10mm.Both bars are

welded on frame in vertical direction. One hole is provided for bearings mounting purposed.

3. Two ball bearings are selected of the standard 6000 ball bearings.

These bearings are mounted in hole of rectangular bar.

Outside diameter of selected bearing is 25mm and internal diameter is 10mm. Bearings are

provided for smooth working of wheels during actual working of system.

4. One shaft of cast iron material is used for mounting of wheels. Shaft is cut in required

dimensions as per the attachment of wheels. Diameter of shaft is 10mm and 6mm at both

ends.

5. Polyurethane tubes are used for connecting solenoid valve ports to cylinder ports.

Diameter of tube is 6mm. Connector are used to connect the tube to port and avoid the air

leakage.

6. One pneumatic cylinder is used for braking purposed. Cylinder is operated through

compressed air from compressor.

Inlet port of cylinder is connected to port B of solenoid valve and outlet port is connected to

A port of solenoid valve.

7. One solenoid valve is used for controlling the passage of air toward the cylinder and

forward and backward moment of piston.

Main port of valve, inlet port is connected to compressor discharged port. Port A and B are

connected to cylinder. For actuation of valve, a connection of control circuit is given to valve.

8. One DC motor is used to free rotation of wheels during working.

External power supply is given to motor and motor is attached to one wheel out of both.

9. IR sensor is used for detection of obstacles and connection of IR circuit is given to control

unit which further activate the solenoid valve.


10. One compressor is used in system for purposed of air which required for braking system.

The compressor pressured should be within 2-5bar.

Photograph 3.4: sensor operated intelligent braking system


CHAPTER FOUR

PERFORMANCE ANALYSIS AND TESTING

4.1 Technical specifications of component used in system

4.1.1. Specification of Pneumatic Cylinder:

Force:

To determine the size cylinder that is needed for a particular system, certain

Parameters must be known. First of all, a total evaluation of the load must be made.

This total load is not only the basic load that must be moved, but also includes any

Friction and the force needed to accelerate the load. Also included must be the force

Needed to exhaust the air from the other end of the cylinder through the attached

Lines, control valves, etc. Any other force that must be overcome must also be

Considered as part of the total load. Once the load and required force characteristics

are determined, a working pressure should be assumed. This working pressure that

is selected must be the pressure seen at the cylinder's piston when motion is taking

place. It is obvious that cylinder's working pressure is less than the actual system

pressure due to the flow losses in lines and valves.

With the total load (including friction) and working pressure determined, the

cylinder size may be calculated using Pascal's Law. Force is equal to pressure being

applied to a particular area. The formula describing this action is:

Force = Pressure * Area

Force is proportional to pressure and area. When a cylinder is used to clamp or

press, its output force can be computed as follows: F = P * A

P = pressure (PSI (Bar) (Pascal's))

F = force (pounds (Newtons))

A = area (square inches (square meters))


Figure.4.1: Pneumatic cylinder

Table.4.1: Component of pneumatic cylinder

Sr

No.

Component Material

1 Piston rod High alloy stainless steel

2 Bearing cap Wrought aluminum alloy

3 Cylinder barrel High alloy stainless steel

4 End cap Wrought aluminum alloy

Speed:

Speed of the piston rod depends upon floe rate of air. The volume per seconds entering in

the cylinder must be change in volume per second inside. It follows than that:

Q m^3/ s = Area X distance moved per second

Where,

Q is the volume of compressed air and this change with the pressure.

Power:

Mechanical power is defined as the Force X velocity. This makes easy to calculate the power

of the cylinder. Compressed air power is more than the mechanical power output because of

friction between sliding parts.

P = F v watts

Basic principle:

Figure.4.2 Shows some of the basic principles of drawing pneumatic circuit diagrams, the

Numbers in the diagram correspond to the following points:


Figure.4.2: Principle diagram of pneumatic cylinder

1. When the manual switch is not operated, the spring will restore the valve to its original

Position.

2. From the position of the spring, one can deduce that the block is operating. The other block

Will not operate until the switch is pushed.

3. Air pressure exists along this line because it is connected to the source of compressed air.

4. As this cylinder cavity and piston rod are under the influence of pressure, the piston rod is

In its restored position.

5. The rear cylinder cavity and this line are connected to the exhaust, where air is released.

4.1.2. Specification of DC Motor:

DC motors consist of one set of coils, called armature winding, inside another set of coils or a

set of permanent magnets, called the stator. Applying a voltage to the coils produces a torque

in the armature, resulting in motion.

Stator:

The stator is the stationary outside part of a motor.

The stator of a permanent magnet dc motor is composed of two or more permanent magnet

pole pieces.

The magnetic field can alternatively be created by an electromagnet. In this case, a DC coil

(field winding) is wound around a magnetic material that forms part of the stator.


Rotor:

The rotor is the inner part which rotates.

The rotor is composed of windings (called armature windings) which are connected to the

external circuit through a mechanical commutator.

Both stator and rotor are made of ferromagnetic materials. The two are separated by air-gap.

Winding:

A winding is made up of series or parallel connection of coils.

Armature winding - The winding through which the voltage is applied or induced.

Field winding - The winding through which a current is passed to produce flux (for the

electromagnet)

Windings are usually made of copper.

Torque developed:

The equation for torque developed in a DC motor can be derived as follows.

The force on one coil of wire F =i l x B Newton

Note that l and B are vector quantities

Since B = /A where A is the area of the coil,

Therefore the torque for a multi turn coil with an armature current of Ia:

T = K Ia (2)

Where is the flux/pole in weber, K is a constant depending on coil geometry, and Ia is the

current flowing in the armature winding.

Note: Torque T is a function of force and the distance, equation (2) lumps all the constant

parameters (Eg. Length, area and distance) in constant K.

The mechanical power generated is the product of the machine torque and the mechanical

speed of rotation, m

Or, Pm = m T

= m K Ia (3)

It is interesting to note that the same DC machine can be used either as a motor or as a

generator, by reversing the terminal connections.


Voltage: 12 VDC

Output Power: 1.1 W

Gear Ratio:

1:20 or 1:60

For Gear Ration

Rated Speed:



Rated Torque:



Rated Current: 0.41 A

Encoder Resolution: 60 counts per revolution

Weight: 160 g

Diameter: 37 mm

Shaft diameter: 5.5 mm

Figure.4.3: DC motor


4.1.3 Specification of IR sensor:

Infrared radiations is the electromagnetic waves in the wavelength region longer than the

visible light wavelength, lying from 0.75m to 100m. the wavelength. Region of 0.75 to

3m is called as near infrared, the region of 3m to 6m is called as middle infrared, and the

region of 6m to 15m is called as far infrared.

An infrared radiation has the following characteristics:

1. Invisible to human eyes.

2. Small energy.

3. Long wavelength.

4. Emitted from all kinds of objects or obstacles.

A typical system for detecting infrared radiations consists of following parameters:

1. Infrared sources: infrared sources include blackbody radiations , tungsten lamps,

silicon carbide and other sources. In addition of these radiant sources, infrared lasers

that emit infrared energy of a specific wavelength are used .

2. Transmission media: Typical Ex. Of infrared transmission media include the

atmosphere and optical fibers. The bandwidth from 3m to 5m and 8m to 12m,

where the rate of absorption is lower, are sometime called as atmospheric windows

and are often used for sensing application

3. Optical system: to coverage of focus infrared radiations, optical lenses made up of

quartz, CaFe2, Ge and Si, polyethylene Fresnel lenses, mirrors made up AL,AU

materials are use according to wavelengths.

4. Detector: there are two types of infrared detector, one is thermal type which has no

wavelength dependence, and second one quantum type that is wavelength dependent.

5. Signal processing: signal output from detector generally small and needs to amplified.

When designing preamplifier, it is necessary to consider impedance that match the

detectors, low noise and bandwidth. If the detector is cool, it is also cooled the

amplifier.


4.1.4 Specifications of polyurethane tubes:

Figure.4.4: Polyurethane tube

Features:

The polyurethane tube, featuring excellent flexibility, helps compact piping requiring small

bending radius.

Tubes come in a variety of colors so that pipings can be identified by color or can be

completed in the same colors as the devices.

Specifications:

Fluid Admitted- Compressed air

Serviced pressured gauge- 0~100psi(0~0.7Mpa)

Working vacuum: -29.5in Hg(-100Kpa)

Service temperature range: -5~140C (no freezing)

Model designation:

Ex. UB 0640 20 B

UB-model code

0640-tube diameter (outer diameter/inner diameter)

20-tube length

B-tube colour


4.1.5 Specifications of Direction Control Valve:

Directional control valves start, stop or change the direction of flow in compressed air

applications. Valves are designed for different applications and a factory may use several

different types of valves with each being suited for a particular job.

Figure.4.5: 5/2 direction control valve

Material Used:

Body: aluminum

Actuator: zinc die cast

Spool : stainless steel

Bushes : brass

Seals: viton (valve body) Nitrile (solenoid)

Technical information:

Type: spool valve

Style body: ported

Port size: g1/8

Mounting: any plane

Temperature range: -100c to +550c

Pneumatic information:

Pressure range: vacuum to 10 bar

Minimum spring return: 3 bar

Nominal: 3,2mm


4.2 Cost Estimation:

Table.4.2: Raw material cost

Sr. No Description Qty Material Cost

01 Pneumatic cylinder 01 STD 2500

02 Auto 5/2 valve 01 STD 2000

03 Bearing 02 STD 150

04 Bearing housing 02 EN-9 250

05 Bush material 02 EN-9 50

06 Pneumatic connector 05 STD 350

07 Angels ......... M.S. 600

08 Pneumatic tubes STD 120

09

Shaft material ......... M.S. 150

10 Sensor and electrical parts STD 5000

11 Nuts and bolts ............ STD 100

11270/-

Table.4.3: Operation Cost

Operation Rate Rs/hr Total time hrs Total cost

Milling 110 1.25 HRS 140

Lathe 90 2.35 HRS 220

Drilling 10r / drill ................ 60

Cutting 40 ............... 150

Total 570/-


Table.4.4: Miscellaneous cost

Operation Cost

Gas cutter 150

Fabrication 700

Total 850/-

Table.4.5: Machining cost

Grinding 150

Hardening 85

Fuel charges 700

Color charges 200

Total 1135/-

Total cost: - Row Material cost + Machine cost + miscellaneous cost + cost of Parches cost +

overhead the total cost of m/c = 13825/- only


CHAPTER FIVE

PROCESS SHEET

Process sheet generally consists of the total operation required and carried on each component

during the designing and developing the project.

Process sheet for various parts used in project as per following order:

5.1 Process sheet No.01

Part name: bearing mounter-1

Part weight- 1 kg

Part material- M.S

Part quantity-2 Nos.

Part size- 120mm50mm10mm

Table.5.1. Process sheet for bearing mounter

Sr. No Operation Machine Tool Time

01 Cutting the material as per our

required size.

Power

Hacksaw

Hacksaw blade 10 min

02 Drilling 10mm hole. Lathe

machine

Drilling bit

10mm

10 min

03 Make diameter 26mm. Lathe

machine

Boring tool 15 min

Same operations are carried out for another bearing mounter.


Part name: lower frame

Part material - M.S

Part quantity-1

Part size-2 nos of 500mm 400mm and 4nos. 150mm


Table.5.2: Process sheet for frame

Sr.

No.

Operation Machine Tool Time

1 Cutting the material as per our

required size.

Power

hacksaw

Hacksaw blade 40

min

2 Welding of a frame Arc welding Welding

holder

40

min


Part name: -wheel connecting shaft

Row Material Size: - 26512mm

Material : - EN 9

Quantity : - 01 Nos.

Table.5.3: Process sheet for wheel connecting shaft

Sr. No. Operation Machine Tool Time

1. Clamp Stock on Lathe Lathe Single Pointe

Cutting Tool

10 min

2. Wheel shaft size Through Thickness Lathe Single Pointe

Cutting Tool

10 min

3. Shaft size 12 Through Thickness Lathe Single Pointe

Cutting Tool

15 min

4. Shaft finishing 10 Through

Thickness

Lathe Finishing Tool 15 min


CHAPTER SIX

CONCLUDING REMARKS

6.1 Conclusion and Result:

[1] Intelligent braking system is the braking system of future. The interdisciplinary

interaction of mechanic and electronics provides its greatest benefits sensors, valves and

pneumatic cylinder work together and allow totally novel, highly dynamic brake.

[2] In this system, Sensors unit sense the obstacle which cannot be judge easily by basic

human beings. This sensor gives control signal and process of application of brake is done

within the few seconds.

[3] The intelligent braking system is useful in avoiding the damage and accidents occurs

during the parking of vehicle in parking side specially when driver parking a vehicle from rear

side

6.2 Advantage Disadvantage And Application Of System:

6.2.1 Advantage of system:

[1] Avoid damage and accidents during parking of vehicle.

[2] Brake cost will be low.

[3] Less power consumption system

[4] Free from wear adjustment.

[5] As the system consists of pneumatic operations, whole system will pollution free.

[6] Installation is very simple and less costly

[7] System will open up new ideas and opportunities in automobile industry

6.2.1 Disadvantages of system:

[1] As the pneumatic parts are quite costly, system will required additional cost.

[2] If there is fault in working of sensor or control circuit, will create problem in system. So

its better way that sensor should be properly installed


6.2.2 Applications of system:

[1] As there is major problem happens during the parking of vehicle that vehicle damage or

critical accidents. So this system is applicable in modern as well as regular vehicle as the

parking system.

[2]This system is also applicable in automobile industry, as advanced breaking system.

6.3 Future scope of system:

The regular demands and requirements of human beings are increases for comfort and safe

driving.

Most of time it seems that the problem is creates during parking of vehicle.

Driver unable to judge the actual and approximate distance at such time which results into

damage of vehicle or serious accidents.

Thus this advance system in breaking will open up new concept to automobile industry.

There is no recent research on parking problems so this system will helpful to over come from

such problems.


REFERENCES

[1] Adams, N.D., et al., 1996, Warehouse & Distribution Automation Handbook, McGraw-

Hill.

[2] Apple, J.M., 1972, Advanced Braking System Design, New York: Ronald.

[3] Bartholdi, III, J.J., and Hackman, S.T., 2011, Warehouse & Distribution Science,

version0.95, http://www.isye.gatech.edu/~jjb/wh/book/editions/wh-sci-0.95.pdf.

[4] Frazelle, E., 2002, World-Class Warehousing and Automated System, S.T. Jhonson.

[5] Kulwiec, R.A., Ed., 1985, Pneumatic Controls Handbook, 2nd Ed., New York: Wiley.

[6] Mulcahy, D.E., 1994, Electronic Sensors & Control Unit Handbook, McGraw-Hill.

[7] Mulcahy, D.E., 1999, Industrial Handbook, New York: S.T. Jhonson

4. Project Report Intelligent Breaking System 2

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