1

CONTENTS

ABSTRACT -IV

LIST OF FIGURES -V

1. INTRODUCTION -5

1.1. TYPES OF BRAKES -8

1.1.1. MECHANICAL BRAKES -11

1.1.2. HYDRAULIC BRAKES -12

1.1.3. AIR BRAKES -13

1.1.4. ELECTRICAL BRAKES -13

1.1.5. VACCUM BRAKES -14

1.1.6. REGENERATIVE BRAKES -14

1.2. IR SENSOR -16

1.2.1. SENSORS -16

1.2.2. TYPES OF SENSORS -16

1.2.3. IR TRANSMITTER -18

1.2.4. IR RECIEVER -18

2. LITERATURE SURVEY -19

3. COMPONENTS AND DESCRIPTION -21

3.1. SELECTION OF PNEUMATICS -21

 2

3.2. PNEUMATIC COMPONENTS AND

ITS DESCRIPTION -21

3.2.1. PNEUMATIC SINGLE ACTING CYLINDER -22

3.2.2. SOLENOID VALVE -26

3.2.3. FLOW CONTROL VALVE -28

3.2.4. IR SENSOR UNIT -29

3.2.4.1. IR TRANSMITTER CIRCUIT -30

3.2.4.2. IR RECIEVER CIRCUIT -31

3.2.5. WHEEL AND BRAKE ARRANGEMENT -32

3.2.6. CONNECTOR, REDUCER, HOSE COLLAR -33

3.2.7. STAND -33

3.2.8. SINGLE PHASE ACTING INDUCTION MOTOR -33

3.3. BLOCK DIAGRAM OF IBS -37

3.4. CIRCUIT DIAGRAM OF IBS -38

3.5. LAYOUT OF THE IBS -39

3.6. WORKING OPERATION -42

4. APPLICATIONS AND ADVANTAGES -44

5. COST ESTIMATION -45

6. CONCLUSION -46
 3

7. REFERENCES -47

ABSTRACT

Braking is nothing but bringing a moving vehicle or moving body to a stop.

Nowadays safety is an important feature in the automotive industry. The intelligent
braking system is the next step to automation. Presently cars have the alarm system
where when the car gets too close to an object an alarm is triggered which warns
the driver about an object close by. But this feature has produced lot of problems
and are prone to human error. We have enhanced the facility by using the same
system but we have altered it so that the car brakes automatically when an obstacle
is close by.

The aim is to design and develop a control system based on intelligent

electronically controlled automotive braking system is called “INTELLIGENT
REVERSE BRAKING SYSTEM”. Sensor Operated Pneumatic Brake consists of
 4

IR transmitter and Receiver circuit, Control Unit, Pneumatic breaking system. The
IR sensor is used to detect the obstacle. There is any obstacle in the path, the IR
sensor senses the obstacle and giving the control signal to the breaking system. The
pneumatic breaking system is used to brake the system. So basically here the car
brakes on its own by determining the distance from the object.

LIST OF FIGURES

Chapter Name Of The Figure Page Number

3.2.4.1 IR Transmitter circuit 30
3.2.4.2 IR Receiver circuit 31
3.2.8 Capacitor start motors 34
3.2.8 Split Phase motor 36
3.2.8 Permanent Split Capacitor Motor 36
3.3 Block Diagram 37
3.4 Circuit Diagram 38
3.5 Layout Of IBS 39
3.5 Experimental Setup-1 40
3.5 Experimental Setup-2 41
 5

INTRODUCTION

We have pleasure in introducing our new project “INTELLIGENT

BRAKING SYSTEM”, which is fully equipped by IR sensors circuit and
Pneumatic breaking circuit. It is a genuine project which is fully equipped and
designed for Automobile vehicles. This forms an integral part of best quality.

The “PNEUMATIC BRAKING CIRCUIT” can stop the vehicle within 2

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

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
 6

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.

• Full automation.
• Semi automation.

In semi automation a combination of manual effort and mechanical

power is required whereas in full automation human participation is very
negligible.

NEED FOR AUTOMATION:

Automation can be achieved through computers, hydraulics, pneumatics,

robotics, etc., of these sources, pneumatics form an attractive medium for low cost
automation. The main advantages of all pneumatic systems are economy and
simplicity. Automation plays an important role in mass production.

For mass production of the product, the machining operations decide the
sequence of machining. The machines designed for producing a particular product
are called transfer machines. The components must be moved automatically from
the bins to various machines sequentially and the final component can be placed
 7

separately for packaging. Materials can also be repeatedly transferred from the
moving conveyors to the work place and vice versa.

Nowadays almost all the manufacturing process is being atomized in order to

deliver the products at a faster rate. The manufacturing operation is being
atomized for the following reasons.

• To achieve mass production

• to reduce man power

• To increase the efficiency of the plant
• To reduce the work load
• To reduce the production cost
• To reduce the production time
• To reduce the material handling
• To reduce the fatigue of workers
• To achieve good product quality
• Less Maintenance
 8

TYPES OF BRAKING

The brakes for automotive use may be classified according the following
considerations.

1. PURPOSE
2. LOCATION
3. CONSTRUCTION
4. METHOD OF ACTUATION
5. EXTRA BRAKING EFFORT
 9

Based on the above considerations, brakes are classified with respect to

following factors.

1. With respect to application,

a. Foot brake
b. Hand brake

2. With respect to the number of wheels,

a. Two wheel brakes
b. Four wheel brakes

3. With respect to the method of braking contact

a. Internal expanding brakes
b. External contracting brakes

4. With respect to the method of applying the braking force.

a. Single acting brake
b. Double acting brakes.

5. With respect to the brake gear,

a. Mechanical brake
b. Power brakes

6. With respect to the nature of power employed

 10

a. Vacuum brake
b. Air brake
c. Hydraulic brake
d. Hydrostatic brake
e. Electric brake

7. With respect to power transmission,

a. Direct acting brakes
b. Geared brakes

8. With respect to power unit,

a. Cylinder brakes
b. Diaphragm brake

The foot brake or service brake is always applied by a pedal, while the
parking brake is applied by a hand lever. The parking brake is intended chiefly to
hold the car in position. The parking brake can be set in the “ON” position by
means of a latch while the service brake remains on only as long as the driver
presses down on the pedal.

The hand brake is normally used only after the driver has stopped the car by
using the foot brake. Its other use is as an emergency brake to stop the car if the
foot braked system should fail. The hand or parking brakes operates on a pair of
wheels, frequently the rear wheels. When drum type rear brakes are used, the same
shoes can be used for both hand and foot control.
 11

The drum type of brake may either be a band brake or a shoe brake. Both
band brakes and shoe brakes may be either external or internal. The band brakes
generally are external and shoe brakes internal. In drum brakes the drum is
attached to the wheel and revolves with it. Friction to slow the drum is applied
from inside by the shoes which do not rotate but are mounted on a stationary metal
back plate. There are different types of drum brakes such as a two leading shoe
arrangement – which gives an augmented response to pedal effort because of its
self applying arrangement. A leading-trailing shoe is a cheaper and better
alternative as it is equally effective whether the car is going forward or backwards.

Manufacturers design drum brakes so that rain, show or ice or grit cannot
get inside and decrease braking efficiency for moisture greatly reduces the friction
between the linings and the drum.

The dissipate quickly the considerable amount of heat generated when

braking a fast moving heavy car large brake drums would be required. Disc brakes
do the job more efficiently, for the cooling air can get to the rubbing between each
piston and the disc, there is a friction pad held in position by retaining pins, spring
plates etc. Passages are drilled in the caliper for the fluid to enter or leave the each
housing. These passages are also connected to another one for bleeding. Each
cylinder contains a rubber selling ring between the cylinder and the piston.
 12

The brakes are applied, hydraulically actuated piston move the friction pads
into contact with the disc, applying equal and opposite forces on the later. On
releasing the brakes, the rubber sealing rings act as return springs and retract the
pistons and the friction pads away from the disc.

MECHANICAL BRAKE:

In a motor vehicle, the wheel is attached to an auxiliary wheel called

drum. The brake shoes are made to contact this drum. In most designs, two shoes
are used with each drum to form a complete brake mechanism at each wheel. The
brake shoes have bake linings on their outer surfaces. Each brake shoe is hinged at
one end by on anchor pin; the other end is operated by some means so that the
brake shoe expands outwards. The brake linings come into contact with the drum.
Retracting spring keeps the brake shoe into position when the brakes are not
applied. The drum encloses the entire mechanism to keep out dust and moisture.
The wheel attaching bolts on the drum are used to contact wheel and drum. The
braking plate completes the brake enclosure, holds the assembly to car axle, and
acts the base for fastening the brake shoes and operating mechanism.

HYDRAULIC BRAKES:
 13

The hydraulic brakes are applied by the liquid pressure. The pedal force is
transmitted to the brake shoe by means of a confined liquid through a system of
force transmission.

The force applied to the pedal is multiplied and transmitted to brake shoes
by a force transmission system. This system is based upon Pascal’s principle,
which states that “The confined liquids transmit pressure without loss equally in all
directions”.

It essentially consists of two main components – master cylinder and wheel

cylinder the master cylinder is connected by the wheel cylinders at each of the four
wheels. The system is filled with the liquid under light pressure when the brakes
are not in operation. The liquid is known as brake fluid, and is usually a mixture of
glycerin and alcohol or caster-oil, denatured alcohol and some additives Spring
pressure, and thus the fluid pressure in the entire system drops to its original low
valve, which allows retracting spring on wheel brakes to pull the brake shoes out of
contact with the brake drums into their original positions. This causes the wheel
cylinder piston also to come back to its original inward position. Thus, the brakes
are released.

AIR BRAKE:

Air brakes are widely used in heavy vehicle like buses and trucks which
require a heavier braking effort that can be applied by the driver’s foot. Air brakes
are applied by the pressure of compressed air, instead of foot pressure, acting
 14

against flexible diaphragms in brake chamber. The diaphragms are connected to

the wheel brakes. These diaphragms are controlled through a hand or foot
operated valve. The brake valve controls brake operation by directing the flow of
air from a reservoir against diaphragms in the brake chamber when the brakes are
applied and from brake chambers to tube atmosphere when the brakes are released.
The air compressor, driven by the engine furnishes compressed air to the reservoir
fall below a set valve.

ELECTRIC BRAKE:

Electric Brakes are also used in some motor vehicles, although these are not
very popular. Warner electric brake is one of the examples of such brakes. An
electric brake essentially consists of an electromagnet within the brake drum. The
current from the battery is utilized to energize the electromagnet, which actuates
the mechanism to expand the brake shoe against the brake drum, thus applying the
brakes. The severity of braking is controlled by means of a rheostat, which is
operated by the driver through the foot pedal.

Electric brakes are simpler. These brakes do not require complicated

operating linkage. Only cable is required to take current from the battery to the
electromagnet. Also, these are very quick in action as compared to other types of
brakes.

VACUUM BRAKES / SERVO BRAKES:

 15

A serve mechanism fitted to the braking system reduces the physical effort
the driver has to use on the brake pedal most servo mechanisms are of the vacuum
assistance type. A pressure differential can be established by subjecting one side
of the piston to atmospheric pressure and the other side to a pressure below
atmospheric pressure by exhausting air from the corresponding end of the servo
cylinder.

REGENERATIVE BRAKING:

Electricity powered vehicles use regenerative braking for stopping the

vehicle. With regenerative braking pressing the brake pedal does not necessarily
activate a conventional friction brake. The motor controller controlling the vehicle
is treated as a generator which slows the vehicle and simultaneously provides an
output for charging the battery. The effectiveness of regenerative braking falls of
with vehicle speed. Electric vehicles will have to be fitted with conventional
hydraulic friction brakes as well as with regenerative systems.
 16

IR SENSOR

SENSORS

A sensor is a transducer used to make a measurement of a physical

variable. Any sensor requires calibration in order to be useful as a measuring
device. Calibration is the procedure by which the relationship between the
measured variable and the converted output signal is established.
 17

Care should be taken in the choice of sensory devices for particular

tasks. The operating characteristics of each device should be closely matched to
the task for which it is being utilized. Different sensors can be used in different
ways to sense same conditions and the same sensors can be used in different ways
to sense different conditions.

TYPES OF SENSOR:

Passive sensors detect the reflected or emitted electro-magnetic radiation

from natural sources, while active sensors detect reflected responses from objects
which are irradiated from artificially generated energy sources, such as radar. Each
is divided further in to non-scanning and scanning systems.

A sensor classified as a combination of passive, non-scanning and non-

imaging method is a type of profile recorder, for example a microwave
radiometer. A sensor classified as passive, non-scanning and imaging method, is a
camera, such as an aerial survey camera or a space camera, for example on board
the Russian COSMOS satellite.

Sensors classified as a combination of passive, scanning and imaging are

classified further into image plane scanning sensors, such as TV cameras and
solid state scanners, and object plane scanning sensors, such as multi-spectral
scanners (optical-mechanical scanner) and scanning microwave radiometers.
 18

An example of an active, non-scanning and non-imaging sensor is a profile

recorder such as a laser spectrometer and laser altimeter. An active, scanning and
imaging sensor is radar, for example synthetic aperture radar (SAR), which can
produce high resolution, imagery, day or night, even under cloud cover.

The most popular sensors used in remote sensing are the camera, solid state
scanner, such as the CCD (charge coupled device) images, the multi-spectral
scanner and in the future the passive synthetic aperture radar.

Laser sensors have recently begun to be used more frequently for monitoring
air pollution by laser spectrometers and for measurement of distance by laser
altimeters.

In our project IR transmitter and IR receiver are used to detect the obstacle. These
sensors are fitted at the front side of the vehicle.

IR TRANSMITTER:

The IR transmitting circuit is used in many projects. The IR transmitter

sends 40 kHz (frequency can be adjusted) carrier under 555 timer control. IR
carriers at around 40 kHz carrier frequencies are widely used in TV remote
controlling and ICs for receiving these signals are quite easily available.

IR RECEIVER:

The transmitted signal reflected by the obstacle and the IR receiver

circuit receives the signal and giving control signal to the control unit. The control
unit activates the pneumatic breaking system, so that break was applied.
 19

LITERATURE SURVEY

Pneumatics
The word ‘pneuma’ comes from Greek and means breather wind. the
word pneumatics is the study of air movement and its phenomena is derived from
the word pneuma. Today pneumatics is mainly understood to means the
application of air as a working medium in industry especially the driving and
controlling of machines and equipment.

Pneumatics has for some considerable time between used for carrying
out the simplest mechanical tasks in more recent times has played a more
important role in the development of pneumatic technology for automation.
 20

Pneumatic systems operate on a supply of compressed air which must

be made available in sufficient quantity and at a pressure to suit the capacity of the
system. When the pneumatic system is being adopted for the first time, however it
wills indeed the necessary to deal with the question of compressed air supply.

The key part of any facility for supply of compressed air is by means
using reciprocating compressor. A compressor is a machine that takes in air, gas at
a certain pressure and delivered the air at a high pressure.

Compressor capacity is the actual quantity of air compressed and

delivered and the volume expressed is that of the air at intake conditions namely at
atmosphere pressure and normal ambient temperature.

The compressibility of the air was first investigated by Robert

Boyle in 1962 and that found that the product of pressure and volume of a
particular quantity of gas.

The usual written as

pv = c (or) pivi = p2v2

In this equation the pressure is the absolute pressured which for free is
about 14.7 psi and is of courage capable of maintaining a column of mercury,
nearly 30 inches high in an ordinary barometer. Any gas can be used in pneumatic
system but air is the mostly used system now a days.
 21

COMPONENTS AND DESCRIPTION

SELECTION OF PNEUMATICS:

Mechanization is broadly defined as the replacement of manual effort by

mechanical power. Pneumatics is an attractive medium for low cost mechanization
particularly for sequential or repetitive operations. Many factories and plants
already have a compressed air system, which is capable of providing both the
power or energy requirements and the control system (although equally pneumatic
control systems may be economic and can be advantageously applied to other
forms of power).
 22

The main advantages of an all-pneumatic system are usually economy

and simplicity, the latter reducing maintenance to a low level. It can also have
out standing advantages in terms of safety.

PNEUMATIC COMPONENTS AND ITS DESCRIPTION

The pneumatic bearing press consists of the following components to fulfill
the requirements of complete operation of the machine.

1) PNEUMATIC SINGLE ACTING CYCLINDER

2) SOLENOID VALVE
3) FLOW CONTROL VALVE
4) IR SENSOR UNIT
5) WHEEL AND BRAKE ARRANGEMENT
6) PU CONNECTOR, REDUCER, HOSE COLLAR
7) STAND
8) SINGLE PHASE INDUCTION MOTOR

1) PNEUMATIC SINGLE ACTING CYLINDER:

Pneumatic cylinder consist of

A) PISTON B) CYLINDER

The cylinder is a Single acting cylinder one, which means that the air
pressure operates forward and spring returns backward. The air from the
 23

compressor is passed through the regulator which controls the pressure to required
amount by adjusting its knob.

A pressure gauge is attached to the regulator for showing the line pressure.
Then the compressed air is passed through the single acting 3/2 solenoid valve for
supplying the air to one side of the cylinder.

One hose take the output of the directional Control (Solenoid) valve and
they are attached to one end of the cylinder by means of connectors. One of the
outputs from the directional control valve is taken to the flow control valve from
taken to the cylinder. The hose is attached to each component of pneumatic system
only by connectors.

CYLINDER TECHNICAL DATA:

Piston Rod:

M.S. hard Chrome plated

Seals:

Nitrile (Buna – N) Elastomer

End Covers:

Cast iron graded fine grained from 25mm to 300mm

 24

Piston:

-Aluminium.

Media:

-Air.

Temperature Range:

0°c to 85°c

Parts of Pneumatic Cylinder

Piston:
The piston is a cylindrical member of certain length which reciprocates
inside the cylinder. The diameter of the piston is slightly less than that of the
cylinder bore diameter and it is fitted to the top of the piston rod. It is one of the
important parts which convert the pressure energy into mechanical power.

The piston is equipped with a ring suitably proportioned and it is relatively

soft rubber which is capable of providing good sealing with low friction at the
operating pressure. The purpose of piston is to provide means of conveying the
pressure of air inside the cylinder to the piston of the oil cylinder.

Generally piston is made up of

 Aluminium alloy-light and medium work.

 Brass or bronze or CI-Heavy duty.
 25

The piston is single acting spring returned type. The piston moves forward
when the high-pressure air is turned from the right side of cylinder.

The piston moves backward when the solenoid valve is in OFF condition.
The piston should be as strong and rigid as possible. The efficiency and economy
of the machine primarily depends on the working of the piston. It must operate in
the cylinder with a minimum of friction and should be able to withstand the high
compressor force developed in the cylinder and also the shock load during
operation.

The piston should posses the following qualities.

a. The movement of the piston not creates much noise.

b. It should be frictionless.
c. It should withstand high pressure.

Piston Rod
The piston rod is circular in cross section. It connects piston with piston of
other cylinder. The piston rod is made of mild steel ground and polished. A high
finish is essential on the outer rod surface to minimize wear on the rod seals. The
piston rod is connected to the piston by mechanical fastening. The piston and the
piston rod can be separated if necessary.
One end of the piston rod is connected to the bottom of the piston. The
other end of the piston rod is connected to the other piston rod by means of
coupling. The piston transmits the working force to the oil cylinder through the
piston rod. The piston rod is designed to withstand the high compressive force. It
 26

should avoid bending and withstand shock loads caused by the cutting force. The
piston moves inside the rod seal fixed in the bottom cover plate of the cylinder.
The sealing arrangements prevent the leakage of air from the bottom of the
cylinder while the rod reciprocates through it.

Cylinder Cover Plates

The cylinder should be enclosed to get the applied pressure from the
compressor and act on the pinion. The cylinder is thus closed by the cover plates
on both the ends such that there is no leakage of air. An inlet port is provided on
the top cover plate and an outlet ports on the bottom cover plate. There is also a
hole drilled for the movement of the piston.

The cylinder cover plate protects the cylinder from dust and other particle
and maintains the same pressure that is taken from the compressor. The flange has
to hold the piston in both of its extreme positions. The piston hits the top plat
during the return stroke and hits the bottom plate during end of forward stroke. So
the cover plates must be strong enough to withstand the load.
Cylinder Mounting Plates:
It is attached to the cylinder cover plates and also to the carriage with the
help of ‘L’ bends and bolts.

2. SOLENOID VALVE WITH CONTROL UNIT:

The directional valve is one of the important parts of a pneumatic system.

Commonly known as DCV, this valve is used to control the direction of air flow in
the pneumatic system. The directional valve does this by changing the position of
its internal movable parts.
 27

This valve was selected for speedy operation and to reduce the manual
effort and also for the modification of the machine into automatic machine by
means of using a solenoid valve. A solenoid is an electrical device that converts
electrical energy into straight line motion and force. These are also used to operate
a mechanical operation which in turn operates the valve mechanism. Solenoids
may be push type or pull type. The push type solenoid is one in which the plunger
is pushed when the solenoid is energized electrically. The pull type solenoid is one
is which the plunger is pulled when the solenoid is energized.
The name of the parts of the solenoid should be learned so that they can be
recognized when called upon to make repairs, to do service work or to install them.

Parts of a Solenoid Valve

1. Coil
The solenoid coil is made of copper wire. The layers of wire are separated
by insulating layer. The entire solenoid coil is covered with an varnish that is not
affected by solvents, moisture, cutting oil or often fluids. Coils are rated in various
voltages such as 115 volts AC, 230 volts AC, 460 volts AC, 575 Volts AC, 6 Volts
DC, 12 Volts DC, 24 Volts DC, 115 Volts DC & 230 Volts DC. They are
designed for such frequencies as 50 Hz to 60 Hz.

2. Frame
The solenoid frame serves several purposes. Since it is made of laminated
sheets, it is magnetized when the current passes through the coil. The magnetized
coil attracts the metal plunger to move. The frame has provisions for attaching the
mounting. They are usually bolted or welded to the frame. The frame has
provisions for receivers, the plunger. The wear strips are mounted to the solenoid
frame, and are made of materials such as metal or impregnated less fiber cloth.
 28

3. Solenoid Plunger
The Solenoid plunger is the mover mechanism of the solenoid. The plunger
is made of steel laminations which are riveted together under high pressure, so that
there will be no movement of the lamination with respect to one another. At the
top of the plunger a pin hole is placed for making a connection to some device.
The solenoid plunger is moved by a magnetic force in one direction and is usually
returned by spring action.Solenoid operated valves are usually provided with cover
over either the solenoid or the entire valve. This protects the solenoid from dirt
and other foreign matter, and protects the actuator. In many applications it is
necessary to use explosion proof solenoids.

WORKING OF 3/2 SINGLE ACTING SOLENOID (OR) CUT OFF VALVE:

The control valve is used to control the flow direction is called cut off
valve or solenoid valve. This solenoid cut off valve is controlled by the emergency
push button. The 3/2 Single acting solenoid valve is having one inlet port, one
outlet port and one exhaust port. The solenoid valve consists of electromagnetic
coil, stem and spring. The air enters to the pneumatic single acting solenoid valve
when the push button is in ON position.

Technical Data:

Size : ¼”

Pressure : 0 to 7 kg / cm2

Media : Air

Type : 3/2
 29

Applied Voltage : 230V A.C

Frequency : 50 Hz

3. FLOW CONTROL VALVE:

1. Technical Data:

Size : ¼”

Pressure : 0 to 10 kg / cm2

Media : Air

(b) Purpose:

This valve is used to speed up the piston movement and also it acts as an one
– way restriction valve which means that the air can pass through only one way
and it can’t return back. By using this valve the time consumption is reduced
because of the faster movement of the piston.

4. IR SENSOR UNIT:-
 30

The IR transmitter and IR receiver circuit is used to sense the obstacle. It is

fixed to the back side of the frame stand with a suitable arrangement. The
pneumatic cylinder is controlled by the flow control valve, single acting solenoid
valve and control unit.

AT NORMAL CONDITION:

The IR transmitter sensor is transmitting the infrared rays with the

help of 555 IC timer circuit. These infrared rays are received by the IR receiver
sensor. The Transistor T1, T2 and T3 are used as an amplifier section. At normal
condition Transistor T5 is OFF condition. At that time relay is OFF, so that the
vehicle running continuously.
31
32
 33

AT OBSTACLE CONDITION:

At Obstacle conditions the IR transmitter and IR receiver, the

resistance across the Transmitter and receiver is high due to the non-conductivity
of the IR waves. So the output of transistor T5 goes from OFF condition to ON
stage. In that time the relay is ON position. In that time, the solenoid valve is on so
that the vehicle stops.

5. WHEEL AND BRAKING ARRANGEMENT:

The simple wheel and braking arrangement is fixed to the frame stand. Near
the brake drum, the pneumatic cylinder piston is fixed.

6. CONNECTORS, REDUCER AND HOSECOLLAR:

In our pneumatic system there are two types of connectors used; one is the
hose connector and the other is the reducer. Hose connectors normally comprise
an adapter (connector) hose nipple and cap nut. These types of connectors are
made up of brass or Aluminium or hardened steel. Reducers are used to provide
inter connection between two pipes or hoses of different sizes. They may be fitted
straight, tee, “V” or other configurations. These reducers are made up of gunmetal
or other materials like hardened steel etc.
 34

7. STAND:

This is a supporting frame and made up of mild steel.

SINGLE PHASE INDUCTION MOTOR:-

It is found to drive the roller shaft which fixed on the end of the frame
structure. The free end of the shaft in the motor a large pulley is found around
which the belt runs. The other specification about the motor is discussed in design
part of the machine.

Single-Phase Theory

Because it has but a single alternating current source, a single-phase motor

can only produce an alternating field: one that pulls first in one direction, then in
the opposite as the polarity of the field switches. A squirrel-cage rotor placed in
this field would merely twitch, since there would be no moment upon it. If pushed
in one direction, however, it would spin.

The major distinction between the different types of single-phase AC motors

is how they go about starting the rotor in a particular direction such that the
alternating field will produce rotary motion in the desired direction. This is usually
done by some device that introduces a phase-shifted magnetic field on one side of
the rotor.

The figure the performance curves of the four major types of single-phase
AC motors. They are described below.
 35

Split-Phase Motors:
The split phase motor achieves its starting capability by having two separate
windings wound in the stator. The two windings are separated from each other.
One winding is used only for starting and it is wound with a smaller wire size
having higher electrical resistance than the main windings. From the rotor's point
of view, this time delay coupled with the physical location of the starting winding
produces a field that appears to rotate. The apparent rotation causes the motor to
start.

A centrifugal switch is used to disconnect the starting winding when the

motor reaches approximately 75% of rated speed. The motor then continues to run
on the basis of normal induction motor principles.
 36

Capacitor-Start Motors

Capacitor start motors form the largest single grouping of general purpose
single phase motors. These motors are available in a range of sizes from fractional
through 3HP.

The winding and centrifugal switch arrangement is very similar to that used
in a split phase motor. The main difference being that the starting winding does not
have to have high resistance. In the case of a capacitor start motor, a specialized
capacitor is utilized in a series with the starting winding.

The addition of this capacitor produces a slight time delay between the
magnetization of starting poles and the running poles. Thus the appearance of a
rotating field exists. When the motor approaches running speed, the starting switch
opens and the motor continues to run in the normal induction motor mode.

This moderately priced motor produces relatively high starting torque, 225
to 400% of full load torque. The capacitor start motor is ideally suited for hard to
start loads such as conveyors, air compressors and refrigeration compressors. Due
to its general overall desirable characteristics, it also is used for many applications
where high starting torque may not be required. The capacitor start motor can
usually be recognized by the bulbous protrusion on the frame where the starting
capacitor is located.
 37

Permanent-Split Capacitor Motors

The capacitor of this motor is left in series with the starting winding during
normal operation. The starting torque is quite low, roughly 40% of full-load, so
low-inertia loads such as fans and blowers make common applications.

Running performance and speed regulation can be tailored by selecting an

appropriate capacitor value. No centrifugal switch is required.
 38

BLOCK DIAGRAM

IR

POWER TRANSMITTER
SUPPLY CONTROL UNIT

IR RECEIVER

FLOW
CONTROL SOLINOID
VANVE VALVE

PNEUMATIC BREAK
CYLINDER
ARRANGEME
AIR TANK
 39

CIRCUIT DIAGRAM
 40

LAYOUT OF THE INTELLIGENT BRAKING SYSTEM

 41

EXPERIMENTAL SETUP-I
 42

EXPERIMENTAL SETUP-II
 43

WORKING OPERATION

The important components of our project are,

• IR transmitter
• IR receiver
• Control Unit with Power supply
• Solenoid Valve
• Flow control Valve
• Air Tank (Compressor)

The IR TRANSMITTER circuit is to transmit 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 receiver circuit is called “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.

If the solenoid valve is activated, the compressed air passes to the Single
Acting Pneumatic Cylinder. The compressed air activate the pneumatic cylinder
and moves the piston rod.

If the piston moves forward, then the breaking arrangement activated. The
breaking arrangement is used to break the wheel gradually or suddenly due to the
piston movement. The breaking speed is varied by adjusting the valve is called
“FLOW CONTROL VALVE”.
 44

In our project, we have to apply this breaking arrangement in one wheel as a

model. The compressed air drawn from the compressor in our project. The
compressed air flow through the Polyurethene tube to the flow control valve. The
flow control valve is connected to the solenoid valve.
 45

APPLICATIONS AND ADVANTAGES

APPLICATION:

• For automobile application

• Industrial application

ADVANTAGES

• Brake cost will be less.

• Free from wear adjustment.
• Less power consumption
• Less skill drivers is sufficient to operate.
• It gives very simplified operation.
• Installation is simplified.
• To avoid other burnable interactions viz.… (Diaphragm) is
not used.
 46

COST ESTIMATION

MATERIAL COST:

Sl. No. Qty. Amount (Rs)

PARTS
i. Single Acting Pneumatic Cylinder 1 1200
ii. Flow Control Valve 1 600
iii. Wheel 1 500
iv. Solenoid Valve 1 600
v. Single Phase induction motor 1 2000
vi. Sensor Unit 1 800
vii. Pulley 1 80
viii. Polyethylene Tube - 60
ix. Hose Collar and Reducer - 150
X Stand (Frame) 1 250

TOTAL COST =Rs. 6240+Rs. 260 (miscellaneous cost)

=Rs. 6500

CONCLUSION
 47

This project work has provided us an excellent opportunity and experience,

to use our limited knowledge. We gained a lot of practical knowledge regarding,
planning, purchasing, assembling and machining while doing this project work.
We feel that the project work is a good solution to bridge the gap between
institution and industries.
We are proud that we have completed the work with the limited time
successfully. The INTELLIGENT PNEUMATIC BRAKE is working with
satisfactory conditions. We are able to understand the difficulties in maintaining
the tolerances and also quality. We have done to our ability and skill making
maximum use of available facilities.

In conclusion remarks of our project work, let us add a few more lines about
our impression project work. Thus we have developed an “INTELLIGENT
BRAKING SYSTEM” which helps to know how to achieve low cost automation.
The application of pneumatics produces smooth operation. By enhancing this
technique, the system can be modified and developed according to the applications.

REFERENCES
 48

1. G.B.S. Narang, “Automobile Engineering”, Khanna Publishers, Delhi,

pp 671.
2. William H. Crowse, “Automobile Engineering”.
3. Donald. L. Anglin, “Automobile Engineering”.
4. Pneumatic Control System----Stroll & Bernaud, Tata Mc Graw Hill
Publications.
5. Pneumatic System----Majumdhar, New Age India International (P) Ltd
6. Automotive electronics in passenger cars –A.Numazawa

Web sites:

www. Profc.udec.cl/~gabriel/tutorials.com

www.carsdirect.com/features/safetyflatures

www.hwysafety.org

www.Wikipedia.com

www.Crazyengineers.com

www.howstuffworks.com