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CONTENTS

Chapter Contents Page no:

ACKNOWLEDGEMENT 5
ABSTRACT 6

LIST OF FIGURES AND LIST OF 7

TABLES
1 INTRODUCTION 8
2 LITERATURE SURVEY 9
3 ELEMENT TYPE USED IN THE PROJECT 10
MATERIALS
3.1 Aluminium 11
3.2 Copper 12

3.3 Material composition 13

RESULT AND DISCUSSION
4 ADVANTAGE AND DISADVANTAGES
OF RECTANGULAR FINS AND EDGE 15
ROUNDED FINS
5 TEMPERATURE RESULTS 16
6 HELIX RESULTS 17
7 CONCLUSION & REFERENCE 18 -19
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ACKNOWLEDGEMENT

I take this opportunity to express my deepest sense of gratitude and sincere thanks to
everyone who helped me to complete this work successfully.

I express my whole hearted thanks to the management of the college

Chairman, NMIET for providing me an opportunity to do studies in this esteemed institution.

I would like to express deepest appreciation towards Dr.Niranjan Mishra principal

for providing the facilities for my studies and constant encouragement in all achievements

I express my sincere thanks to Dr.Santosh Kumar Sahu, Head of Department,

Mechanical Engineering, NMIET College of Engineering and Technology for providing me with
all the necessary facilities and support.

I would like to place on record my sincere gratitude to my seminar guide

Mr.Sangram Behera, Professor, Mechanical Engineering,NMIET College of Engineering and
Technology for the guidance and mentorship throughout the course.
ABSTRACT

Now-a-days, accidents taking place are very frequent in India which occur mainly due to the inefficiency
of driver to apply brakes at the right time. This is also because of rise in population of vehicles which if
not handled properly may create difficulty in driving vehicles on road. A system must be designed to
minimize accidents which may compensate for the inability of the drivers to apply brakes at the right
time. Therefore our aim is to design and develop an electronically intelligent braking system which can
automatically sense the objects ahead of the vehicle and applies brakes itself to avoid collision. If the
collision still happens then we can add a new technology of retractable/extractable bumper which may
extract in case of collision and avoids the damage to the vehicle’s body. This bumper may extract or
retract with the help of using Pneumatics technology which is much easier to implement and is readily
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available easily. Hence in this project we aim to design and develop "Automatic Pneumatic Bumper and
BrakingSystem=.
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LIST OF FIGURES

Figure No: Figure Name: Page No:

3 SOLID-45 GEOMETRY 10

4.1 ALUMINIUM RADIATOR FINS 11

4.2 COPPER RADIATOR FINS 12

5.1 NORMAL 13
RECTANGULAR MODEL
FINS

5.2 EDGE ROUNDED MODEL 13

FINS

5.3 NORMAL RECTANGULAR 14

MODEL FINS

5.4 EDGE ROUNDED MODEL 14

FINS

LIST OF TABLES

Table No: Table Name: Page No:

7.1 TEMPERATURE RESULTS 16

8.1 HELIX RESULTS 17

CHAPTER 1

INTRODUCTION

Vehicles account for about one-third of India's population. As a result, fatalities caused by
automobile collisions undoubtedly lead to the majority of deaths. Though there are many reasons for
these collisions, one of the most frequent is the driver's inability to apply brakes at the appropriate time.

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As a result, installing and incorporating an automatic bumper and braking mechanism is important for
vehicles to avoid accidents. We created an Automatic Pneumatic Bumper and Braking Mechanism to
accomplish this system.

The bumper, which is completely fitted with an infrared sensor and a pneumatic bumper control
circuit, is the main part of this system. We give a collision control system called the extractable and
retractable bumper (E/R bumper) in this project. The E/R bumper is usually stowed, but when a high
probability of a frontal impact collision is observed, the bumper extracts to provide more crush space.
The kinetic energy of a motor vehicle caused by a collision is then quickly transformed into work by
plastic deformation of the bumper's structure. The car is decelerated in a comparatively short time and
distance during this energy conversion phase.

The IR sensor on the E/R bumper detects the barrier, and if the obstacle is within 1-1.2 feet of the
car, a control signal is sent to the bumper and split triggering device. This bumper activation device is
triggered only when the vehicle speed exceeds 40-50 km/h. To detect this speed, a proximity sensor is
mounted in the system, and the signal is transmitted to the control unit and pneumatic bumper
activation system, respectively, and the bumper removes, preventing damage to the vehicle's body.
CHAPTER 2
LITERATURE SURVEY

Srinivasa Chari.V et al (2018) reported that, if an obstacle is within 3-4 feet of the vehicle, a
control signal is sent to the bumper activation system and the pneumatic braking system at the same
time.
Only when the vehicle speed exceeds 30-40 km/h is this bumper and braking system enabled.[1]

Shinde Aniket S et al (2017) have conducted a study that the control signal is provided if there is
some obstacle closer to the vehicle. braking machine with bumper activation system This smart braking
system is a groundbreaking project aimed at avoiding or reducing the effects of frontal accidents that
occur on congested roads. This system is built on the "Smart braking system with pneumatic bumper," a
smart electrically controlled automatic bumper and brake activation system. This device also improves
vehicle braking response time to maintain a healthy gap between two vehicles.[2]
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Mr. Lakhan Thombare et al (2016) studied and determined the failure to apply the brakes at the
appropriate time is the most common reason given. Accidents can be avoided if the brakes are applied at
the appropriate time. When compared to fully manual braking, automation will ensure greater braking
efficiency. Because of its simplicity and ease of operation, pneumatic systems can be useful in
automation. As a result, the aim is to design and implement a system based on vehicle automatic control.
As a result, our aim is to create an "Intelligent Braking Device with Pneumatic Bumper."[3]

Mayur K. Gadhave et al (2017) observed and reported, the aim is to design and build a control
system based on "Intelligent Braking with Pneumatic Bumper," an intelligent electronically controlled
automotive bumper activation system. The IR transmitter and receiver circuits, the Control Unit, the
pneumatic bumper system, and the braking unit are all part of this system. The obstacle is detected using
the infrared sensor. The control signal is sent to the bumper activation device braking unit if there is
some obstacle closer to the vehicle. The pneumatic bumper system protects both the man and the car.
Vehicle collisions are a big issue nowadays.[4]
CHAPTER 3

CONSTRUCTION AND WORKING

As this system is used at the time of emergency during work in normal travelling of vehicle this system is
off and it never impact on the normal working. When any obstacle, humans, animals or vehicle is come
in front of the vehicle then the installed infrared sensor senses that obstacle. The range of distance
between the vehicle and obstacle is variable. This range is varied according to the density of vehicles or
humans on road. The received signal by IR sensor is provided to the control unit. This control unit
operates the relay according to the input signal. The relay operated by control unit cut off the electric
power supply given to the engine so the working of engine is stop. When the engine stops the working
the motion of vehicle suddenly reduces. At the same time of working of IR sensor the driver also applied
the brakes so, braking system works by two methods. There are some incidents when the working of
automatic braking works and engine running also stop. But due to the moment of inertia on vehicle tries
to forward motion of the vehicle. This inertia motion causes accidents. During such incidence the driver
also uses manual braking system. In this manual braking system limit switch is also installed below the
brake pedal.

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Fig 3.1: Automatic Breaking System

By receiving the foot force of driver the limit switch activates and provides the signal to the
solenoid control valve. Solenoid control valve open sport going towards the bumper system and brake
shoes. This pneumatic force used to forward motion of the bumper. By receiving the impact of accidental
force bumper try to deflects. The flexible nature of the bumper is able to sustain the force and so the
impact of this force on vehicle is reduced. When the external body is kept safe then there is no chance of
inner damage.
CHAPTER 4

MATERIALS AND METHODS

Technical specification of materials that we used

4.1 The Cylinder

The cylinder converts the energy of compressed air into the linear motion. The air enters the
cylinder and pushes the piston from one end of the cylinder to the other. There are two main types of
cylinders-single acting and double acting. A single acting cylinder has only one air connection while a
double acting has two. In single acting cylinder, the piston is forced out by the pressure of air. When the
air supply is removed and air inside the cylinder is allowed to piston moves back, driven by the force of
spring.

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By restricting the escaping air (exhaust), it is possible to slow down the return movement of the
piston. The double acting cylinder has two air connections. When compressed air is supplied to one
connector and the end is allowed to exhaust to atmosphere (i.e. the air is allowed to escape freely), the
piston is driven to the other end of the cylinder. When air is then applied to second connector and first is
allowed to exhaust to the atmosphere, the piston returns back. This type of cylinder gives more power
on return stroke than single acting cylinder .Also ensures that piston is effectively locked in the position
at both ends of its stroke. Pneumatic cylinders (sometimes known as air cylinders) are mechanical
devices which produce force, often in combination with movement, and are powered by compressed gas
(typically air).

4.2 Limit switch

A mechanical limit switch interlocks a mechanical motion or position with an electrical circuit. A
good starting point for limit-switch selection is contact arrangement. The most common limit switch is
the single-pole contact block with one NO and one NC set of contacts; however, limit switches are
available with up to four poles. Here we required to sends an electrical pulse to electronic relay circuit.
So we used a simple normally closed limit switch. This sends electric current when driver stands from his
seat. When driver on his seat, his weight presses down the limit switch and then it is in open mode. We
have to send a 12 volt dc voltage through the circuit. So we select KW-8 series limit switch, which can
passes 0 to 25 volt dc.

4.3 Solenoid valve

Solenoid valve is used in automatic brake system to control the compressed air towards the brake
chamber during the brake needed and release the compressed air when driver release the parking brake.
Different types of solenoid valves are available in the market. But most common is ½ solenoid valve and
2/5 solenoid valve. ½ indicates one way operation and two ports and 2/5 indicates two way operation
and five ports.

4.4 Basic frame

This project, automatic brake system, is a demonstration model. We used a simple AC motor with

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belt drive to rotate the wheel disc. Basic frame is formed by mild steel angle and the complete unit is
fitted on the frame. Seat is made of sheet metal of gauge 18. A spring is fitted below the seat to prevent
the action of limit switch due to seat’s weight
Ac motor used is 230 volt, 50Hz, single phase, ½ Hp of electrical motors. V-belts and pulleys are
used to rotate the brake drum with a reduction of 1:4.

4.5 Emergency switch

Emergency switch is a simple electrical switch. Common type one way switch is used in this
project. This switch can provide the same action of limit switch, when driver needs brake in emergency.
4.6 Electronic relay circuit

Electronic relay circuits are electromechanical switching devices. They have two outputs. The two
outputs are connected to two solenoid valves. The electronic relay provides electric current to a solenoid
valve at a time.
CHAPTER 5

CONCEPTS

The project is combination of the mechanical and Electronics, which is fairly known as the Mechatronics.
Mechatronics is a combination of field of engineering that includes relations of systems engineering,
mechanical engineering, electrical engineering, telecommunication engineering, control engineering and
computer engineering. The upcoming world is full of Automation so we need to develop a system which
is fully automatic.

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Figure 5.1. Concept of Mechatronics

5.1 IR transmitter and Receiver

The IR TRANSMITTER circuit is to transmit the Infra-Red rays. If any obstacle is there in a path,
the Infra-Red rays reflected. The reflected Infra-Red rays from the obstacle are received by the receiver
circuit is called <IR RECEIVER=. The IR TRANSMITTER circuit is to transmit the Infra-Red rays. If
any obstacle is there in a path, the Infra-Red rays are reflected. This reflected Infra-Red rays are received
by the receiver circuit which is called as called <IR RECEIVER=. The Infrared receiver circuit receives
the reflected IR rays from the obstacle and giving the control signal to the control circuit. The control
circuit is used to activate the solenoid valve. This system works when driver does not apply brake
manually In this case the chances of accident are very high. When any obstacle is detected by IR sensor
the signals are sending to both braking and bumper system. Thus the brakes are applied and bumper is
activated. This system can help to save the people sitting inside the vehicle and also will save the external
body of vehicle from getting damaged.

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CHAPTER 6

OBJECTIVES

1) To increase the sureness of braking Application.

2) To increase the response time of braking system.

3) To improve the pre-crash safety.

4) To avoid the percentage of passenger injury by using external vehicle safety.

5) To reduce the requirement of internal safety devices like air bags.

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CHAPTER 7

RESULTS

We got that by giving 4 to 8 bar pressure of compressor and speed 2m/sto our work model, we
found that if any obstacle comes in front of the vehicle automatic bumper will move forward with help
of pneumatic system and will increase the crashing distance between the two vehicles. The model
which we have created will stop the vehicle by applying brake for the distance of 0.15m in 1sec.

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CHAPTER 8

CONCLUSION

Automatic brake system is an additional safety to heavy vehicles. 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 lathe and small scale
industries. Project has been designed to perform the entire requirement task at the shortest time
available. The aim of our project is to improve the prevention technique of accidents and also reducing
the hazard from accidents like damage of vehicle, injury of humans, etc.

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CHAPTER 9

FUTURE SCOPE

Our future work deals with incorporating this system with various different features to provide
enhanced protection by the automatic braking system in real time application:

Infrared sensor can be replaced by hydraulic bumper.

Regular bumper can be replaced by hydraulic bumper.

Infrared sensor can sense eye blinking and give signal to solenoid valve when driver sleep.

Bumper design can further be enhanced to act as external air bags.

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CHAPTER 10 REFERENCE

[1]. Katore S.R., Kadlag S.C., Mane P.V., Pawar G.V., Prof.Londhe B.C., <Automatic Braking With
Pneumatic Bumper System=, 2015, International Journal Of Engineering, Education And Technology
(Ijeet), Volume 3, Issue 2.
[2]. TejsinhPisal, AkshayPatil,et al., <Design and development of pneumatic bumper with automatic

braking system=2017.

[3]. Shinde A.S., Hivrekar A.P.et al., <Smart Breaking System With Pneumatic Bumper=2017.

[4]. Jadhav N. D., Gulmire S.M., Ghutukade R.S., Gaikwad A.S., Prof.Fegade S.G. <Automatic Braking
With Pneumatic Bumper System= 2015,Ijsart Volume 1 Issue 5.

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