Project Report Intelligent Breaking System 2
Project Report Intelligent Breaking System 2
Project Report Intelligent Breaking System 2
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.
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.
Page 1 of 30
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.
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.
Page 2 of 30
CHAPTER TWO
LITERATURE REVIEW
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.
Intelligent Braking System
Page 3 of 30
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.
Page 4 of 30
CHAPTER THREE
SYSTEM MODELING
Intelligent Braking System
Length: 500mm
Width:
Height: 150mm
400mm
Page 5 of 30
25mm
Stroke: - 50mm
12V DC
Page 6 of 30
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.
POWER
SUPPLY
FLOW
CONTROL
VALVE
AIR
COMPRSSOR
CONTROL
UNIT
IR
TRANSMITTER
IR
RECEIVER
SOLENOID
VALVE
PNEUMATIC
CYLINDER
BRAKE
APPLY
Page 7 of 30
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:
Height:
400mm
150mm
Page 8 of 30
Specification of cylinder:
Cylinder Sr.No.:30825-95166
Bore:-25mm
Stroke:-50m
Page 9 of 30
R2
3.3.4. DC Motor:
Figure.3.7: DC motor
Page 10 of 30
Specification of DC motor:
Voltage
: 12 VDC
: 1:20 or 1:60
3.3.5. IR Sensor:
Figure.3.8: IR sensor
Page 11 of 30
3.3.6. Compressor:
Figure.3.9: Compressor
Page 12 of 30
Page 13 of 30
Page 14 of 30
10. One compressor is used in system for purposed of air which required for braking system.
The compressor pressured should be within 2-5bar.
Page 15 of 30
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))
Page 16 of 30
Sr
Component
Material
No.
1
Piston rod
Bearing cap
Cylinder barrel
End cap
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:
Intelligent Braking System
Page 17 of 30
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.
Page 18 of 30
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.
Page 19 of 30
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)
62 RPM (for gear ratio 1:60)
Rated Torque:
8.84 N.cm (for gear ratio 1:20)
28.4 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
Figure.4.3: DC motor
Page 20 of 30
Page 21 of 30
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
Page 22 of 30
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.
Pneumatic information:
Pressure range: vacuum to 10 bar
Minimum spring return: 3 bar
Nominal: 3,2mm
Intelligent Braking System
Page 23 of 30
Description
Qty
Material
Cost
01
Pneumatic cylinder
01
STD
2500
02
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
STD
5000
11
STD
100
.........
............
11270/-
Rate Rs/hr
Total cost
Milling
110
1.25 HRS
140
Lathe
90
2.35 HRS
220
Drilling
10r / drill
................
60
Cutting
40
...............
150
Total
570/-
Page 24 of 30
Cost
Gas cutter
150
Fabrication
700
Total
850/-
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
Page 25 of 30
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
01
02
03
Operation
Machine
Tool
Hacksaw blade
required size.
Hacksaw
Lathe
Drilling
machine
10mm
Lathe
Boring tool
Time
10 min
bit 10 min
15 min
machine
Page 26 of 30
Operation
Machine
Tool
Time
No.
1
hacksaw
Welding of a frame
Arc welding
Hacksaw blade 40
min
Welding
40
holder
min
: - EN 9
: - 01 Nos.
Operation
Machine
Lathe
Tool
Single
Time
Pointe 10 min
Cutting Tool
2.
Lathe
Single
Pointe 10 min
Cutting Tool
3.
Lathe
Single
Pointe 15 min
Cutting Tool
4.
Shaft finishing
10
Through Lathe
Finishing Tool
15 min
Thickness
Page 27 of 30
CHAPTER SIX
CONCLUDING REMARKS
Page 28 of 30
Page 29 of 30
REFERENCES
[1] Adams, N.D., et al., 1996, Warehouse & Distribution Automation Handbook, McGrawHill.
[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
Page 30 of 30